baking+biscuit 2025-02 digital

Welcoming Industry 5.0

Catalina Mihu, Editor-in-chief

Your commments or suggestions are always appreciated: e-mail: mihu@foodmultimedia.de

When ChatGPT exploded into our everyday lives, the effervescence around its uses and opportunities quickly made room for concerns. Undoubtedly, its benefits are immediate and part of its appeal. But, there are also many questions, when looking at the bigger AI picture. Will it use human-made artwork to learn and generate content based on prompts? Will people’s likenesses be used in an unethical way, or without their permission? First and foremost, will Generative AI tools take away jobs from people? Is it a threat to our livelihoods, now or 10 years from now?

As with all revolutionary innovations, profound disruptions are part of the adoption process. The AI landscape comes with significant opportunities, but also carries the weight of critical risks – management-related and stemming from establishing technical implementation. And it does come with drawbacks, as it (currently) lacks the codes for creativity and empathy, for instance. It is also argued that AI can weaken some human skills, as we are increasingly relying on digital tools of all kinds. AI navigation systems make driving so comfortable, for example; but, one might still need to be able to park manually if needed.

As with any new, disruptive technology, adjustments in adopting emerging AI tools are not without struggles. Yes, some jobs are indeed reassigned to smart automation systems, but, they usually address strenuous and repetitive tasks. Smart, human management can train and assign the teams in their organizations to work using these tools, which are ultimately made for our comfort, rather than making people redundant. After all, smart tehcnology and AI are not without flaws and they can be wrong when compiling statistics. The chances of error may be small, but not zero.

Industry 4.0 benefits are widely praised in the baking industry; the ‘smart factories’ are starting to emerge, in unique interpretations, incorporating various intelligent solutions – especially visible in industrial bakeries. What’s the next step in this direction? It must take into consideration the biggest challenges of today, from efficiency to sustainability and ethics.

In October 2024, the European Commission hosted an Industry 5.0 Community of Practice session, to discuss the future of a resilient industry in the EU. The events analyzed the role of Industry 5.0 in enhancing the long-term competitiveness of EU Industries and brainstormed ideas for priorities in 2025. What is Industry 5.0? “Industry 5.0 envisions a future where industries go beyond just efficiency and productivity, focusing on worker wellbeing and using technology for broader prosperity while respecting planetary limits. It places human values at the core of production, driving the digital and green transitions essential for Europe’s long-term success,” the EC defines the concept. Establishing collaboration workflows between humans and machines will be key to sustainable, personalized production.

The main focus of Industry 4.0 has been on automation and smart technologies; Industry 5.0 now adds a new layer to it, bringing humans back to the center of the process, with sustainability at its core. It is a welcome perspective, and one I am looking forward to seeing reflected at iba, soon.

Have a great show, everyone, with meaningful meetings!

Catalina Mihu

COVER STORIES

ALL GREEN LIGHTS FOR THE SMART FACTORY

20/34

HIGHLIGHTS

BAYNE’S THE FAMILY BAKERS IS 70 YEARS YOUNG

IBA ’25 SPECIAL

One of the most important roles a trade show can hope to fulfill is to provide the platform where ideas spark. While bakers get inspiration for new creations from emerging trends, their unique experiences and their customers, at iba they can share their experiences.

Stergiou Family recently expanded its production to a new range –frozen products, with a matching state-of-the-art facility. The fully automated, smart bakery is a project five years in the making, which started operations a few months ago. 40

PRETZELS WITH AN AUTOMATED TWIST

Pretzels are instantly associated with craftsmanship. For production consistency, automation that replicates the craft is the challenge. The MULTITWIST system by FRITSCH earned awards for achieving this.

A baking business with deep roots in the local community it serves, Bayne’s the Family Bakers celebrates 70 years in Scotland’s baking scene. To mark its anniversary, the bakery opened its 70th shop in Perth.

SMART SOURDOUGH BAKING STARTS HERE

Establishing a complete setup for sourdough production in industrial bakeries poses several challenges. Setting up an optimum process flow is fundamental to timing each step with respect to the dough’s development.

CUTTING-EDGE CUTTING

Optimizing bread recipes and fine-tuning their production will guarantee the best results, consistently. Between this bread and perfectly cut, sandwich-ready slices is the right blade.

© Bayne's

VISIT

06 Stergiou Family Bakery, Greece: All green lights for the smart factory

14 MECATHERM Demo Center: Full-scale testing makes perfect

IBA ‘25 SPECIAL

20 Exhibitor preview: Stand highlights

34 The German Baker’s Confederation: Bakers inspire bakers

36 iba organizers: All bakery roads lead to Germany BAKERIES

30 Scotland: Bayne’s the Family Bakers is 70 years young

SNACKS, CRACKERS

40 FRITSCH: Pretzels with an automated twist

54 Reading Bakery Systems: Emithermic® XE baking equals sustainable baking

58 Euromonitor International: A knack for snacks

SOURDOUGH, PART I

44 AMF Bakery Systems: Smart sourdough baking starts here

60 Fedima: Understanding sourdough for a common ground

MIXING

48 Royal Kaak: Mechanical Dough Developers (MDD) for high-speed mixing

CUTTING, SLICING, PACKAGING

50 Kwik Lok: The total package

52 Hansaloy: Cutting-edge cutting

INTERVIEW

62 Adolf Cermak, cetravac: “Curiosity drives innovation”

QUALITY ASSURANCE

70 Anton Paar: For unique products – by any measure

SCIENCE

74 Dr. Alya Homoud, REDA Bake: A classification of leavening agents

SUSTAINABILITY

76 PhenOlives: An olive branch to ingredient waste

REG ULARS

03 Editorial: Welcoming Industry 5.0

56 News

78 News

78 Advertiser directory

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know? Stay in the know, with the industry-first, open-access virtual library! Valuable in-depth information about everything baking, always with you.

The f2m resource library opens soon!

STERGIOU FAMILY BAKERY, GREECE

All green lights for the smart factory

Stergiou Family recently expanded its production to a new range – frozen products, with a matching state-of-the-art facility. The fully automated, smart bakery is a project five years in the making and started operations a few months ago.

+Stergiou Family has been growing together with its network, for over 50 years. From its production facilities just outside Athens, the company bakes and distributes its products in a smooth-running network spanning about 4,000 km from the production facilities, including islands. The business was built around its flawless delivery concept, which has been perfected in time. Efficiency is of the utmost importance, and so is sustainability; the company regularly optimizes its routes to make sure the environmental impact is minimized. Bigger trucks are used for fewer delivery runs, and even the tires are a part of the company’s sustainability work: they are all recycled when replaced. AI is used to optimize their routes, too, with a live monitoring system for all 140 trucks. The ERP not only tracks routes, but also the status of each truck and even the temperature inside. That’s not all: the smart system also allows the bakery to anticipate incoming orders very accurately, so that production runs are optimized in advance.

Sustainability is a key priority of the business: “We recognize the importance of respecting both the environment and the local community, and we take proactive steps to minimize our impact. As part of our commitment, we have invested in renewable energy to offset 25% of our environmental footprint,” according to the company. Moreover, processes and technologies are established to minimize energy loss and reduce food waste.

With its latest, EUR 40 million investment in a second, brand new production facility, the family business has made an

impressive leap forward that stays true to this philosophy: the fully automated, sustainable plant ensures impeccable delivery between processing stages, in-house, too. This expansion was driven by the significant increase in demand for frozen products, particularly from the hospitality industry, as well as supermarkets expanding their bake-off business.

”At Stergiou Family, we are committed to being pioneers in the bakery and snacking sectors. Our aim is for each launch to create value and elevate the way our customers engage with our products, ultimately enhancing their experience and satisfaction.”

A household name

Stergiou Family products are beloved in the whole country. All Greek men know the Stergiou brand: they build a special relationship as they learn to appreciate their sandwiches, croissants and other snacks during their mandatory military service. The bakery has an established tradition of supplying the army, which goes back to when the business started. Around 1958, Georgios Stergiou, the company’s founder and the father of today’s owner – Dimitris Stergiou, was preparing and delivering fresh sandwiches with his tricycle cart in downtown Athens. He quickly created a market for

Dimitris Stergiou, owner, Stergiou Family Bakery

his business, which included army canteens among his first customers. The market proved fruitful: since then, the name Stergiou has been associated with quality, customer service, and reliability.

The family company has tripled its business over the past 10 years; it is now running two plants with a total capacity of 42,000 tons of dough per year, producing 270 types of bakery products, with a team of 330 people. For retail, the portfolio includes a range of packaged goods, distributed with their own trucks to supermarkets, grocery stores and kiosks. In 2015, Stergiou Family Bakery added a segment for HoReCa, with frozen specialties that are sold to hotels, restaurants and cafés all over Greece.

The project: a brand-new production site

The new plant, spanning 40,000 sqm was built in Avlonas – about 40 km away from the first factory, just outside of Athens. It was a concept five years in the making: about two and a half years were spent defining the concept and designing it down to the smallest detail. The development, from blueprint to fully set up facility, took another year and a half, and around six months after that – equipment installation and commissioning. The plant started production on July 24, 2024.

The new industrial plant in Avlonas, Attica, is dedicated to the HoReCa portfolio of frozen products. It truly embodies the Stergiou Family’s vision of a smart plant, designed to reflect their two main priorities: product innovation and state-of-the-art technology, with the optimum setup to streamline processes and a flexible design to match production needs.

When selecting the solutions for the new plant, two critical factors played a dominant role in the decision-making process: one was achieving top-class product quality, with

a focus on the in-house preparation of long-fermentation liquid sourdough, as a key raw material, and a high-end cooling and shock-freezing process, doubled by a state-ofthe-art seep-freezing storage facility.

The second factor was a high level of automation, to optimize production efficiency and flexibility – a truly smart factory of the future, Stergiou underlines.

Industry 4.0 deep freeze warehouse

Product handling at the end of the production line is the first encounter with what makes this plant smart: it is entirely autonomous for all the cold chain process steps, from picking and handling, to storing and shipping. It is also the first area that can be seen when entering the production space, where the visitor is immediately greeted by several Laser Guided Vehicles (LGVs) from the E80, the Italian developer of automated and integrated intralogistics solutions. The LGVs are either neatly ‘parked’, waiting on standby (with a charging station nearby), or at work – carrying the packaged goods for inspection and storage inside the warehouse freezer. From there, the LGVs also load the products into trucks, according to delivery orders and the established routes, so that the products are always immediately available at each stop. Their ‘traffic’ area is clearly marked, while each unit can also detect any obstacle in their operating area. With a 360°-angle vision, thanks to the Proximity Laser Scanner (PLS) devices, they are completely safe, for the people in the facility, for each other, and for the products they handle.

Once a pallet is complete, a signal is sent out to the LGVs that it is ready to be picked up for wrapping. If the pallets run out, the system will have the robots bring more from the drop-off point to the loading station. Each pallet is inspected and will be corrected if the products are not correctly aligned, before wrapping. But, since the system has been

Stergiou Family at a glance

Stergiou Family is proud of its strong heritage and family tradition, built over 50 years. As a leading snacking and bakery company, the company offers a diverse range of fresh bakery products, including cakes, croissants, donuts, and traditional Greek tsoureki. In recent years, the portfolio grew to include the HoReCa sector with an extensive bakery assortment.

Retail products are delivered fresh through its own fleet of 140 trucks, ensuring door-to-door service to supermarkets, minimarkets, and kiosks. Its HoReCa products, which are frozen, are distributed to hotels, restaurants, and coffee shops.

The bakery’s current production capacity exceeds 220 tons of dough per day, with the flexibility to scale up production further. Currently, Stergiou Family employs 330 people across various departments.

calibrated in detail, this hardly ever occurs. Once the pallet is wrapped and labeled, it is again inspected. Pallets that pass the check will be sent into the cold storage, at -22°C. If they don’t meet all requirements, they go back to assembly. Throughout the process sequence, there is no human intervention, anywhere.

A quick walk inside the cold storage completes the picture of the system’s smart setup: only occasional visitors will need the lights to be turned on, to see their way around. LGVs efficiently manage the deep freeze warehouse, which can be set to temperatures as low as -26°C, entirely on their own. They handle the (palletized, wrapped and labeled) products, storing them in the assigned warehouse space, where they are scheduled to stay for around nine days, and loading the selected ones for delivery. The warehouse also shows sustainability was at the top of mind in its design, from the setup of the airflow distribution – for consistent cooling and low noise, to the choice in environmentally friendly refrigerants.

On average, 10 pallets are sorted per hour, according to orders that need to be filled. The deep-freeze storage was designed with growth in mind – as is the entire plant, and is set up to easily accommodate increased production volumes.

The pallets themselves are included in this way of thinking: they are cleaned if they are dusty and thoroughly inspected. Since they are made of wood, not plastic (a choice made

to streamline distribution), it’s very important that they enter the freezer dry. When a pallet does not pass the inspection, the smart handling system assesses each situation for the corresponding action.

”Our roots lie in our rich family heritage, which has shaped our commitment to high standards of value, safety, and ethics.”

Dimitris

A clean plant is a must

Every detail was taken into minute consideration in the design of the facility, including air management: not only are the temperatures in complete control, but the factory is also equipped with a positive pressure system for maximum hygiene and safety. Air only goes out, whenever a door opens, but outside air and particles, or wandering insects, cannot enter the facility.

State-of-the-art breadmaking

A fully automated bread production line was a must for Stergiou Family, for the new plant. Rademaker customdesigned a bread line to match the bakery’s new facility and their unique range of specialties. “The artisan bread line is capable of handling a great variety of dough types to produce artisan-style products, with the flexibility to form various shapes,” Rademaker details.

Stergiou, owner, Stergiou Family Bakery

The starting point of building the custom line was the end result, the products themselves. Key factors included the types of products, recipes, shapes, sizes, weights and production capacity. “Once we had a thorough understanding of these elements, we collaborated with a team of technologists and technicians to design a line configuration that best fits Stergiou’s needs. Together with Stergiou, we finalized the line concept, ensuring seamless integration into the overall bakery facility, as our line is part of a larger process. This required a clear understanding of the preceding and subsequent production processes. Together, we developed the most optimum layout and footprint of the line in order to work around it to efficiently manufacture their products,” Rademaker explains.

A testing stage followed, at the Rademaker Technology Centre (RTC), where bakers from Stergiou and the host’s bread technologists worked together on some of the most important products. Based on the testing results, the technical solutions needed took shape, with recommendations considering the entire production process. The line was first switched on for the final acceptance test in Culemborg, and then installed in Avlona.

Then, while the line was set up in its new home, Rademaker and Stergiou technologists configured the production. Mechanical installation in the new facility took about six weeks and finetuning the process – five months. The advanced technology in the entire facility also implied a learning process, in synchronizing everything. For example, the steam generated at the oven’s entry unexpectedly vanished without the products benefitting from it. The owner recalls, pointing out the steam measurements on the HMI: “Although steam was generated, there was no steam in use. We had to adjust the overpressure in the facility, which we use to keep out insects and dust, to keep the steam from going directly out in the chimneys.”

New technology upgrades

This flexible line features a Dynamic Pre-Sheeting System (DSS) that transforms dough batches into a uniform dough sheet. Several gentle reduction stations then gradually reduce the sheet to the required thickness without compromising the dough’s integrity. In the final forming stage, the dough is shaped through precise, controlled steps to achieve the desired product shape while ensuring weight consistency for optimal efficiency during production. Then the products are deposited onto peelboards and transported to the proofing system.

Rademaker’s latest technology developments were incorporated into this line: “An innovative dynamic hopper transports the dough in a controlled manner, keeping the shape of the dough chunks linear and constant. Area sensors and separate belts carefully guide the chunks in

the sheeter, ensuring size and weight accuracy. Chunk weight and length are exceptionally accurate, leading to a more stable and consistent dough sheet and eventually high-quality baked products,” the Dutch technology maker explains.

”This is industry 4.0! The factory is fully-automated.”

Dimitris Stergiou, owner, Stergiou Family Bakery

Many of the Stergiou doughs contain a high water percentage, meaning the line needs to be able to process liquid and sticky doughs well. In the previous DSS version, oil used to be added to prevent the dough from sticking to the DSS hopper. “In the new update, the oil was replaced by wax, reducing the required amount by a factor of four compared to oil,” Rademaker highlights the latest features the line has received, which are incorporated into Stergiou’s line. This not only makes the line easier to clean, but also brings considerable cost savings. Rademaker estimates the return on investment for the wax distribution system to be only one year. “Cleanability is improved due to easily removable parts and because wax is used instead of oil. But, perhaps even more importantly, the wax version of the DSS creates a more consistent chunk volume and a

corresponding more consistent dough sheet. This results in a higher accuracy on the final product,” Rademaker highlights.

The Stergiou line also features a hybrid dough weighing system, making sure that the dough weight is always correct with no impact on the product shape in the process. In addition, a dough re-work system was integrated, which helps all of the return dough reenter the process, including side trims and omega trims. “Thanks to the controlled distribution of rework dough, the recycling process is highly stable and reliable,” Rademaker explains.

The line also includes a new molding conveyor, with an improved molding performance compared to the previous system. It also includes a simple, single-operator control that allows fast and safe adjustments of the molding table (in height and molding degree), for fast changeovers, easy cleaning and maintenance operations. For maximum process efficiency, the bakery produces one product range per day, and changes production from the HMI for the next day’s shifts.

Switching production between product runs simply involves selecting the required tooling on the operator panel; the machine automatically bypasses any unneeded tools for the chosen product. For maximum efficiency, the line has

easily removable tools, exchangeable scrapers and bins.

The Unique Fit Tooling system ensures no errors will occur during operation and changeovers. Rademaker explains: “Because of the lightweight and more compact tooling, handling and detaching the tools is easy and can be done by one person, with no need for any additional devices.”

Selecting such an important system goes beyond the technical specification sheet. Rademaker’s know-how and their team’s customer approach were determining factors, too: “We understood that they can offer us more than just 10 tons of iron. This is very important. They have experience, they know what they are doing and they have a good system,” Stergiou underlines.

Rademaker shares their approach to a project like this:

“After we came in contact with Stergiou and learned about their production needs, we started a close partnership with them. It was important to listen to their history, philosophy and their future plans. Then, of course, we discussed their products.”

We love sourdough!

Stergiou Family knows consumers love sourdough, which has long been established in Greece. In the new facility, they invested in being able to provide great-tasting,

premium sourdough products, using self-produced sourdough. For this, they set up a fermentation system, to allow time to work its magic (assisted by high-end technology) and produce sourdough in-house under optimum conditions, consistently. A batch of 40,000 liters of sourdough takes 24 hours to be ready for mixes, with all the parameters under complete control in the process, from the temperature to the amount and the pH, as well as the resulting acidity. The bakery’s breads are made with sourdough.

“Consumers like more acidity in their food, in the South of Europe. That's why we like lemon, we like balsamic vinegar, we like these flavors. For bread, this acidity comes from sourdough. So, in terms of taste, we benefit from using it. But, there are many advantages to sourdough, products achieve a better color, the crust is more crispy and the crumb retains more humidity – improved characteristics all around,” Dimitris Stergiou tells us.

New creations, coming up!

Traditional snacks such as cakes, croissants, donuts, and Greek tsoureki are among Stergiou’s popular specialties. But, the company also looks at new, emerging trends: “There is a growing demand for high-protein products, driven by the increasing popularity of protein-focused diets,” they

A smart factory blueprint: Stergiou Family Bakery technology line-up

The complete project was managed in collaboration with WP BAKERYGROUP, and it combines solutions from:

+ E 80: Laser-guided vehicle system

+ Frigo Stahl: refrigeration systems including the deep-freeze robotic warehouse

+ WP BAKERYGROUP: tunnel oven and handling

+ Pattyn: automated packaging line

+ Sancassiano: dough mixing system

+ Sancassiano: liquid ferment production system

+ E 80: inventory management systems

+ Rademaker: dough make up line

The entire project, presenting all the solutions in this project, will be the topic of a separate article.

illustrate. Products made with traditional ingredients, such as sourdough, are also on the consumers’ and Stergiu’s radar.

”As part of our commitment to sustainability, we have invested in renewable energy to offset 25% of our environmental footprint.”

Dimitris Stergiou, owner, Stergiou Family Bakery

New product launches are a key priority for the bakery, as it views regularly renewing its assortment as essential to staying relevant and meeting consumer demands. This is why, potential launches are continuously evaluated and backed up by research. The communication channels are kept open: “Our main sources of inspiration come from consumer research and social listening, which allow us to better understand consumer needs and map emerging trends.” The company maintains a close relationship with customers, developing concepts suitable to their needs. The new line came with the opportunity to introduce a new, trendy product – pinsa with a twist, to appeal to a wider, dynamic market. It’s called Pinsetta. With a high hydration level and an open structure, Pinsetta has a bit more height than the traditional pinsa, to elevate the classic sandwich concept, while allowing it to be sliced comfortably. The new product was launched in February and is already welcomed with excitement. “It contains sourdough, which acts as a natural preservative, ensuring that the product remains fresh for a significantly longer time in the display. It has a 'handcrafted' appearance, yet is fully baked, providing maximum convenience,” Stergiou describes.

Stergiou continues to focus on snacking options, for a reimagined offering that can meet the nutritional needs of those seeking balanced and fulfilling alternatives. In all its creations, the bakery keeps convenience in mind.

Prepared for the future

Looking ahead to the next years, Stergiou set out to continue growing by staying true to our roots while also embracing the future. “Our roots lie in our rich family heritage, which has shaped our commitment to high standards of value, safety, and ethics. We remain dedicated to putting our customers first and maintaining the trust we've built over the years. At the same time, our eyes are looking to the sky, as we actively monitor emerging nutritional trends and technological advancements. Industry 4.0 is guiding us toward adopting innovative solutions that meet the evolving demands of consumers, allowing us to stay ahead while upholding the principles that have made us a leading brand in Greece.”

While the existing plant is modernized and home to five production lines, the brand new facility now runs one bread and bun line for high production volumes of up to 4 tons per hour, depending on the product; but, it is designed to easily expand production capacity with additional lines. In Greece, frozen bakery is a big market and Stergiou is prepared to earn its share. +++

Pinsetta is the newest product in the company's portfolio, launched in February

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Full-scale testing makes perfect

Over the past few years, MECATHERM has transformed its Demo Center in Barembach, France, from a facility where it showcased its technology into a fully functional baking plant, for projects including training, testing and problem-solving of any kind. Work from process improvements to equipment upgrades and full-scale new product development is carried out here.

+For its recent renovation, the Demo Center was not simply equipped with new machinery, but it was also entirely re-envisioned. The 3,000 sqm center, which was MECATHERM’s first equipment manufacturing space 60 years ago (a milestone celebrated in 2024), became a modern center with a fully automated production line and several alternatives for various processes in a modular set-up. It was set up in two distinct areas to replicate the conditions in a bakery – the production room and the baking zone. And that’s not all: the new air management system, which controls the enclosure’s temperature and pressure, is in itself a feature that inspires visiting bakers, for the efficiency and sustainability improvements of this solution.

Sustainability shaped MECATHERM’s overall strategy, and is reflected in the recent investments in renovating the facility, which are perfectly aligned with with their Corporate Social Responsibility (CSR) commitments. “We combine technological innovations with environmental respect. We strive to limit our energy consumption and optimize our waste management daily. We aim to go further by constantly improving our practices. From ambient temperature management to the implementation of a waste management flow and the replacement of lighting to minimize energy consumption, all recent adjustments have been designed to minimize the impact of the Demo Center’s activities,” reveals Simon Heyberger, Demo Center Manager.

The industrial-scale line is at the heart of the modernized space, allowing, for the first time here, baking tests to be conducted under real and controlled conditions. Players in the bakery, pastry and sweet goods sectors, such as millers, ingredient suppliers, or baking tray manufacturers, can conduct tests for a number of processes, from mixing to baking. It is first and foremost a highly specialized working space, designed to accommodate finding results, or developing solutions. It even has dedicated ‘think tanks’, quiet meeting capsule-rooms installed right on the production floor, next to the machinery, to facilitate exchanges, quite literally ‘on the spot’.

Raymond Nogael, MECATHERM President

All MECATHERM technology concepts

Simon Heyberger is in charge of the Demo Center and the team of bakers and pastry chefs who are working for MECATHERM. He offered Baking+Biscuit International a tour of the renewed and improved facility. “The setup allows for a wide range of tests for a diverse array of products: crusty breads, soft breads, pastry products and sweet goods,” he shares. MECATHERM brought more than 25 pieces of industrial equipment here, which are all set up and ready for testing under controlled temperature and humidity conditions.

The production line was recently installed, with several of MECATHERM’s latest technologies, such as the M-NS divider and the M-RT molder, which allow working with hydrated and rested doughs. The line also includes a chamber with three M-UB proofers and a six-meter-high retarder, allowing for smooth product transfer. With these systems, up to three tests of various products can be carried out simultaneously, even with vastly different specialties, such as croissants, baguettes, and bagels.

The KATANA robotic scoring solution from ABI is also integrated on the line, offering different technologies and scoring options: it can swap from ultrasonic blades to waterjet cutting, to ensure accuracy for any type of product, as it adapts according to the product that is to be scored.

A bagel former from ABI is also part of the technology line-up at the Demo Center. It can be used to test a wide range of products.

The oven is always the centerpiece of any baking facility, and the Demo Center in Barembach features not one, but

five different industrial ovens, including a stone oven, a tunnel oven combining radiant or convection baking, and the latest development from MECATHERM, the Vertical M-VT oven, which was awarded at iba 2023. Testing can be performed to compare the best baking process and its corresponding solutions, for the exact results desired.

”Getting

hands-on with the dough and then seeing the process on an industrial scale with all the pieces of equipment allows for rapid skill development and increased autonomy.”

“By conducting tests under real conditions on a complete line, it is also easier for MECATHERM teams to explain to clients the importance of line engineering. For example, we can show them the benefits of all the technologies and solutions embedded in the line that optimize flows, operation, and line performance,” the Demo Center Manager highlights.

The setup is also the best environment for visiting bakers to discover the benefits of the latest solutions or features developed by MECATHERM, as they can immediately observe the impact on their products by hands-on testing. For example, the latest launches are already available for testing: ”We recently launched an automatic hygrometry management option. This patented innovation not only optimizes energy consumption but also has a direct impact on the quality of the finished product,” he explains.

The ‘Bakery Sustainability’ seminar, co-organized with Puratos, took place at the MECATHERM Demo Center

Simon Heyberger, Demo Center Manager, MECATHERM

© MECATHERM

MECATHERM built a fully automated line for a wide range of product tests at the Demo Center

The exit of the M-RT Moulder, adapted for highly-hydrated and rested doughs

More than a renovation: a concept revision

The Demo Center has become much more than a space for demonstrating equipment: the renovation sought to improve testing conditions and integrate CSR into the experience offered to visiting bakers.

To achieve these goals, for the Center and in all its operations, MECATHERM put in place a continuous improvement approach across the company, looking to improve customer satisfaction. And it works, Heyberger underlines: “We have established a structured method of conducting tests with clients. During a test, a dedicated team is mobilized, and everything is meticulously prepared in advance and at each stage. It seems that this approach is successful, as the average satisfaction rating was 9.2/10 for 2024.”

The Center is strategically located at the heart of the Barembach factory, meaning that all MECATHERM’s experts are easily within reach. It didn’t only imply setting up the best technology lineup, but also making sure the team easily synchronizes their day-to-day work with supporting visitor projects. Each working visit is carefully planned in advance, in all details, from the specialists needed for the task, to the ingredients preferred and processes targeted.

Expertise at hand

A team of seven bakers and pastry chefs, each with 10 to 30 years of experience at MECATHERM, is available to support all kinds of projects at the Center. “They are the same teams who support clients, from trials to the commissioning of the equipment or line at the clients’ site. As they are comprehensively familiar with each project, our bakers and pastry chefs know the client's expectations in detail, so they can recommend all the ideal conditions during commissioning,” the Center’s manager explains the collaborative workflow.

In addition, a complete team of specialists in various fields is available on-site to assist with all working visits, from product managers, engineers, designers, expert bakers and pastry chefs, to the entire MECATHERM R&D team.

The work carried out at the Center revolves around knowledge exchange and experimentation. This includes training, seminars and technical tests. “Beyond the product tests conducted by our clients, the MECATHERM Demo Center is also a place of exchange and experimentation where visitors from around the world come to attend training sessions or seminars,” the expert points out. For

this end, the MECATHERM Academy was established, with various training programs combining theory and practice. The ‘Fundamentals of Industrial Bakery in 72 Hours’ training course, for example, is one of the most appreciated programs – and one of many opportunities focusing on specific topics. “Getting hands-on with the dough and then seeing the process on an industrial scale with all the pieces of equipment allows for rapid skill development and increased autonomy,” Heyberger observes.

Expert classes on sustainability

At the end of November 2024, MECATHERM co-organized the ‘Bakery Sustainability’ Seminar, together with Puratos and other partners. This event, held in the newly remodeled facility, brought together important guests from key companies in the bakery, pastry, and sweet goods sectors, to discuss available solutions to address climate change and waste challenges. Innovative solutions were presented, from ingredients for more sustainable baked goods to solutions for reducing the carbon footprint of a production line, and the conversations explored how to drive sustainable practices across the entire bakery value chain, the organizer shares. “MECATHERM presented innovative solutions developed to optimize the energy efficiency of the manufacturing process such as the new patented Hygro Control System

dedicated to convection ovens (example: vertical ovens). They also introduced solutions to reduce product waste such as the product buffer concept with MVD or MDC and the EYE-Q Quality Control System from ABI, integrating artificial intelligence,” the expert highlights the event’s program.

The attendees witnessed live product demonstrations at the Demo Center, focusing on producing baguettes and brioches with a significantly reduced environmental and carbon footprint. These demonstrations highlighted the use of regenerative flour and innovative baking technologies, ensuring that sustainability does not come at the expense of quality. Sensory evaluations of the products were also conducted.

The Demo Center also wants to support new-generation bakers: each year, nearly 150 students come to visit. “We are always delighted to welcome young people and show them the exciting careers our sector offers,” says the Center’s manager. They are often surprised by what the technology can achieve. Solutions integrating Artificial Intelligence, connected services, innovative solutions adapted to sustainability challenges, are among the concepts that can inspire and attract young talent going forward, MECATHERM believes.

Simon Heyberger, Demo Center Manager

The full-scale industrial line can be used for extensive testing, with five industrial ovens to choose from

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EXHIBITOR PREVIEWS, PART II

iba innovation is here

Exhibitors attending iba ’25 are sharing their stand preparations and plans for innovation. The Baking + Biscuit International interviews with exhibitors will be available online at www.bakingbiscuit.com, with additional insights.

ALBERT HANDTMANN

Handtmann ’s iba stand concept is 'THE TASTE OF INNOVATION', with solutions for processing doughs as well as liquid, viscous, stiff, solid, and chunky product masses. A new dough-dividing solution is introduced. It ensures optimal product quality and precise weight accuracy, especially in industrial production, while remaining flexible for different types of dough. Another novelty is a multi-lane co-extrusion process for filling and forming stuffed products, highly flexible across various applications and products with a high filling content, the company underlines. A new multi-lane solution for continuous, oil-free dough dividing will also be showcased. Solutions for other processes such as dosing, forming, and extruding will also be presented, supported by practical digitalization and automation features. +++

AUTOMATIONX

AMF BAKERY SYSTEMS

AMF will highlight its newest technology at iba, including its hydrogen oven and hybrid baking systems. AMF will showcase technology for dough make-up, proofing, baking and packaging, including: a high-seed bun make-up system, a mini Combo make-up system for breads and buns, a Tromp pizza pressing unit, side-injecting machines for buns and rolls, sheeting and laminating systems, complete pizza topping solutions, as well as continuous/tunnel ovens and slicing and bagging units.

The specialist will illustrate its focus on sustainability, digitalization, automation and hygiene. Live baking is also staged at the stand. “Optimizing processes to reduce energy use and minimize waste is crucial,“ AMF highlights. +++

The Austrian automation specialist prepares a full-scale demo of its MES system for iba, including how to measure and analyze production for efficiency improvements. Recipe management and the control of raw material handling systems will also be highlighted.

AutomationX observes: “A growing trend is using AI to support production planning and scheduling. Our priority is to offer a solution adapted to the bakery industry that meets all their requirements: Advanced Planning and Scheduling (APS) closes all open gaps between ERP systems – MES and the production equipment.” It is viewed as a necessity, which is why APS solutions to plan production independently from a single person in the production are an innovation driver.

HALL 13, A 21 HALL 13,

HALL 10, F 31 HALL 10, F 31

For a quick guide through the halls, the exhibitor color codes, per hall, are: Hall 9 – blue, Hall 10 – red, Hall 11 – yellow, Hall 12 – green, Hall 13 – orange, Hall 14 – violet, Hall 15 – purple

HALL

“As production grows in complexity, there are fewer people available who have a total production overview. Hence, the need for software assistance,” Thomas Mühlehner underlines. Another important focus for the solutions developed at

BÖCKER

AutomationX is supporting production teams with accurate information about the performance and quality of their production lines in real-time, to ensure deviations and breakdowns are handled in real-time. +++

At iba, BÖCKER highlights ready-to-use liquid sourdoughs. “Our range offers numerous alternatives with an extra flavor kick. These products are easy to dose, simple to use, and ensure consistent baked goods quality, without the need for complex sourdough management,” the specialist emphasizes. Visitors will find a new product launch at the stand: the BÖCKER Wheat 100 Liquid, a new sourdough product with an intense aroma, suitable for mixed-type breads, hamburger buns, and toast bread. It achieves a distinctive flavor, with a clean label and no added salt. “Thanks to its high concentration, only a small dosage is needed. Its flexibility is evident in its suitability for all dough processes, including long fermentation and combined methods,” BÖCKER explains. Every day, at 11 AM and 4 PM, the company’s bread sommelier,

Martin Göttlich will present the BÖCKER Sourdough Language, a tool for precisely describing sourdough flavors. +++

COATRESA

HALL 9, C 47

HALL 9, C 47

DAWN FOODS

15, A 21 HALL 15, A 21

Coating specialist COATRESA will showcase its new range of coatings, the Testrong PRO. They offer extra non-stick properties (lasting 25 % more time) and extra abrasion resistance (an added 10 % in hardness). “This shows that we keep innovation as a priority year after year,” says Eduard J. Castaño, VP of Marketing & Business Development. COATRESA’s main priority is to develop solutions adapted to the products that each company bakes. “We are looking forward to welcoming all bakers to discuss their baking pan needs and to work together on any bakeware and coating solutions they may require. We will offer non-stick coatings tailored to each baking application, including PFAS-free options, long-lasting coatings, and high-performance solutions.” +++

Dawn Foods will unveil their highly anticipated Global Bakery Trends at iba, delving into consumer behavior, discussing macro industry influences, and spotlighting the latest market developments shaping the bakery landscape.

“Four key trends will be highlighted, exploring their implications for businesses and innovation in the coming years,” Dawn says. A diverse range of solutions will be showcased, highlighting the synergy between Dawn’s and Royal Steensma’s product portfolios for sweet bakery inspiration and innovation.

Dawn’s Total Donut Solutions, Total Cake Solutions and the new Total Cookie Solutions will be featured, showcasing new inspiration with flavor and texture twists and creative combinations with the added Royal Steensma categories Souplesse (flexible fat-based coating), Chocuise (hard set fat-based coating) and Candied Fruit. The Dawn Balance ® range will be exhibited, featuring better-for-you solutions that cater to evolving consumer preferences. Innovations like Pak Perfect ® Donut Glaze and Pak Perfect ® Icing, both with non-sticky properties, will also be showcased. +++

HALL 15, C 20

HALL 15, C 20

HALL

HEUFT

HEUFT specialists will share their expertise on topics including energy, thermal oil, artisan and industrial baking oven systems. The stand will highlight recovery, full energy management and the company’s new, hybrid heat exchanger. “We share all advantages of our preferred heat transfer medium, thermal oil, which enables all types of heat transfer,” HEUFT details.

Solutions from its sister company, ICECOOL, will also be exhibited at the stand. Application technicians from both companies will bake live. “Baking will take place in HEUFT ovens, while cooling and proofing will be carried out in our ICECOOL systems. Let’s engage in an active exchange!” +++

IREKS

ICECOOL SYSTEMS

ICECOOL experts will present environmentally friendly refrigerants and their proofing and cooling systems, including the latest promising refrigerants, such as CO 2 , which has a low GWP value of just 1. All ICECOOL technologies, from cooling, freezing and conditioning systems to blast freezers, use sustainable refrigerants such as CO 2 or R455A.

The SLOWPROOFER will be on display, a technology supporting a long and cool proofing process.

Information about the FRESHBAKER cooling system is also detailed at the stand, a cooling system that ensures consistently available bread of top quality. +++

KWIK LOK

The ingredient specialist sees opportunities in plant-based alternatives that enrich food culture instead of just giving up on some products: “End consumers expect a plant-based diet to offer variety, individuality, new textures and flavors that go far beyond pure imitation meat. New ideas from the VEGRAIN product range are a must at IREKS, where cereals provide the ideal basis for creative, plant-based snack pastries and dishes that offer variety,” the specialist observes. ‘Food moments’ make another trend IREKS focuses on, as baked goods can become a unique and unusual experience, a reward and a social media highlight. IREKS will also share its know-how to support the ‘Tastes of the World’ growing trend. +++

With the ‘Innovation and Sustainability’ theme, Kwik Lok showcases efficient and environmentally conscious solutions at iba, including eco-friendly closure options. “For high volume bakers, come see our fully automatic bagger designed with fewer moving parts for less maintenance and lower costs. It offers unparalleled speed and reliability for high volume operations,” Kwik Lok anticipates. For in-store and artisan bakery, Kwik Lok is also showing the countertop 093 semi-automatic bag closure: “Spend less time closing bags and more time baking and taking care of customers.” 2-D barcodes on Kwik Lok labels will also be presented, for their role in supporting product safety and serve as a communication tool to build consumer trust, expand marketing and branding to help boost sales. +++

HALL 10, D 37 HALL 10, D 37

HALL 15, A 11 HALL 15, A 11

HALL 9, G 11 HALL 9, G 11

HALL 10, D 37

HALL 10, D 37

LANTECH

LORYMA

HALL 9, A 33

HALL 9, A 33

Lantech will exhibit automated case-packing solutions. The manufacturer of end-of-line packaging machines will demonstrate a case-handling unit designed for efficient packaging and shipping of bakery and confectionery products. The C1000 case erector produces up to 30 cases per minute with flexible dimensions. It maintains a 90-degree angle regardless of the nature of the corrugated board, changing temperatures and humidity levels, and varying blank dimensions. The case bottom can be sealed with either hot melt or tape. +++

MERANER MÜHLE GMBH

Meraner Mühle will put gluten-free products and Italian bread in the spotlight at iba this year, introducing gluten-free panettone and dumplings, in addition to its other gluten-free product solutions for muffins, croissants, pizza, flatbreads, grains, white and pretzel breads. The company will present its offer of gluten-free raw materials and mixes for bread and baked goods. The blends can also be produced in organic quality, on request.

The mill’s Lievito Madre natural yeast is produced in its factory in Lana, South Tyrol. It achieves increased dough tolerance and elasticity, acting as a natural baking improver.

A wide range of products will be showcased at iba, made with the Lievito Madre natural yeast for a variety of applications, including ciabatta bread, panettone, pizza, pinsa and focaccia. +++

HALL 15, FOOD6

HALL 15, FOOD6

Loryma will introduce stabilizer systems that can replace egg and milk – Lory ® Stab, with additional functional benefits. Ingredients that add to nutritional characteristics will also be unveiled: “Lory® Protein and Lory® Starch Elara can boost the protein or fiber content while reducing the carb count,” it says. Loryma also presents specialty starches that can support the adhesion of seeds and toppings and provide a great shine or browning on baked goods. Its specialists will hold daily presentations and share insights on May 21, in the lecture area. +++

With the concept ‘Bake the world a little better’, RAPS introduces new solutions, such as improved savory fillings that offer various flavor options for ready-to-eat pastries. Furthermore, “We have created a new concept for adding flavor and color to the dough, with our new liquid ‘Magic Bakery’ products,” the company says. Savory fillings (including vegan) based on vegetables, herbs, meat, fish, or dairy products will be highlighted. Besides the Fresh Line, seasonings and bindings for pies, strudels or other snacks will also be showcased.

The RAPS Coatec process will also be presented, providing materials with a protective layer that shields them from external influences such as temperature, moisture and oxidation. The encapsulation of acids and carbonates allows for the controlled release of ingredients. +++

HALL 15, H 11 HALL 15, H

18.-22. MAY 2025

SOLLICH

HALL 10, H 26 HALL 10, H 26

This year, SOLLICH KG highlights efficiency with high machine availability and improved handling, focusing on the easy and efficient cleaning of its machines and digitalization. The Enromat ® M6-1050 with a new electronic reproducibility aid for mechanical settings (a patented feature) will be exhibited at the show. It has an eccentric decorator SED 1050 to produce a variety of embossed decorations at the outfeed. The system is complemented by a Thermo-Flow®+ KSK 1400 cooling tunnel. A Minicoater MC 420 enrober will run live demonstrations, with an automated decorating device. The Sollcodrop ® ST drop molding system will also be on display; it is used to produce chocolate drops of 3 mm and larger. The SweetConnect ® platform, allowing users to centrally manage all their production machines, will also be presented. +++

HALL 9, D 31 HALL 9,

In the Middleby Bakery Group area, Sveba Dahlen will introduce several new developments. Among them is the SD Amigo – a Smart Control Panel that will be included as standard on the D-Series deck ovens. “With SD Amigo, we have created a control panel that truly makes bakers' daily work easier,” says Åsa Ericsson, Marketing Manager, Sveba Dahlen.

Several machines will be on display at the stand, including the Rack Oven V-Series, a powerful gas-powered rack oven, which is also available in electric and oil-powered versions. The Exodraft will be introduced, an intelligent energy solution for gas-fired rack ovens and tunnel ovens. With advanced heat recovery technology, Exodraft reduces energy consumption, operating costs, and CO 2 emissions. The D-Series deck oven, model D32E, featuring the new SD Amigo control panel and a built-in proofing, will be shown. The S-Series model SRP242, features a combination where the rack oven is gas-powered for the first time in 2025, by popular demand. The Glimek Bread Line will run live demos several times a day. +++

SYNTEGON

9, A 30 HALL 9, 30

Syntegon will present its solutions for cookie and cracker production. “Our stand at the trade fair reflects current market requirements for flexible, automated packaging solutions for an ever-increasing variety of products,” the company anticipates. The heart of the booth will be the new FGCT high-speed count feeder for sandwich cookies, which will have its European premiere at iba. It efficiently groups cookies and loads them into trays while significantly reducing product damage and food waste. It features highly automated technology for maximum flexibility and sustainability. Innovation at Syntegon is primarily driven by three key developments, the company emphasizes: the increasing demand for sustainable packaging solutions, the growing variety of products on the market and the increasing need to automate production. +++

SVEBA DAHLEN

VERHOEVEN BAKERY EQUIPMENT FAMILY

Verhoeven ’s stand will highlight thinking outside the box, illustrated by three of its concepts: turnkey solutions, vacuum cooling & baking systems, and bread recycling solutions. The company introduces a new concept that illustrates the third category: RepeatLoaf – The Final Concept. “This innovative machine concept is a fully automated process to ferment return bread. Within 24 hours, the bread is converted into a dry, stockable powder. The end product has many applications, as an alternative to flour, as decoration or to enrich dough,” Verhoeven explains. A new experience is also in the works: a meeting with Verhoeven’s Avatar Astronaut Baker. Vactoria Verhoeven will introduce herself as the new Vacuum Operational Assistant. Vacuum cooling & baking solutions will be demonstrated live. +++

WIESHEU

HALL 14, D 31

HALL 14, D 31

The group of companies comprising WIESHEU , WACHTEL ABT, Atollspeed, Winnovation and CoBa AfterSales will display their combined expertise in hot-air, deck, rack and hybrid technology.

With its rack and deck ovens, WACHTEL addresses the needs of bakery production facilities. With its in-store baking ovens, WIESHEU focuses on in-store baking at the POS, including branch operations of bakeries and bakery shops as well as food retailers and the convenience sector.

The expertise of both companies are particularly reflected in the jointly developed Dibas blue2 PICCOLO C combination – with the hot-air baking technology of the Dibas blue2 from WIESHEU and the PICCOLO Pro Plus deck oven from WACHTEL. The Atollspeed H series of appliances are also on show. +++

With the theme ‘We move baking’, WP BAKERYGROUP will present artificial intelligence-supported solutions for the entire baking process, focusing on AI-optimized automation and digitalization.

The concepts will be presented via multimedia content at five theme-oriented WP FutureLabs and can be experienced interactively. There, the companies of the WP BAKERYGROUP, WP Bakery Technologies, WP Haton, WP Industrial Bakery Technologies, WP Kemper and WP Riehle will present the AI-supported baking process. The only equipment at the stand links the present with the future: the intelligent WP Kemper mixer. The AI-supported sensor and control system knows how to guide the dough mixing process with different raw material and environmental parameters, just like experienced employees. The fast, intensive mixing of the ingredients and high energy input produce high-quality doughs with the three-zone kneading principle. The WP InnovationCube is the focus of the 500 sqm stand. +++

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Bayne’s is 70 years young

A baking business with deep roots in the local community it serves, Bayne’s the Family Bakers celebrates 70 years in Scotland’s baking scene. To mark its anniversary, the bakery opened its 70th shop, in Perth. Since the beginning, Bayne’s has strived to be a modern business – not just an early adopter, but also an innovator. This is still true today.

+“Love Bayne’s scotch pies!“; “Wish you would open a shop in Livingston”; “I was in a butcher’s [shop] in Edinburgh recently and the woman serving said that Bayne’s were the best. As a true Fifer, it brought a tear to my eye... I like a well-fired [roll]. The taste is superb!“; “I’ve also been a fan of Baynes for years and have the belly to prove it!” – Bayne’s the Family Bakers is a vibrant, wholesome member of its community, as its social media conversations can easily prove it. These are just some of the recent interactions the Scottish bakery and its customers savor together, online (once they’ve enjoyed the baked creations).

Founded by John Bayne in Lochore, Fife, Bayne’s reached a milestone this February, when it opened its 70th shop in Inveralmond Retail Park, Perth, which also marks the 70th anniversary of the family business. This new shop is the fourth located in Perth (so far) for the bakery, joining those on Dunkeld Road, South Street, and Rannoch Road.

A modern bakery

From a single bakery in Lochore, Fife, Bayne’s has flourished into a beloved Scottish institution, renowned for its quality baking and strong local connections. The traditional home bakery founded by John Bayne is now a leading player in the bakery food-to-go market. Today, the company operates 70 shops across Scotland. What’s notable, a third of the shops in Bayne’s network are under 10 years old: “A decade ago, we had 490 colleagues supporting 52 shops. Today, we’ve nearly doubled our workforce to 960, ensuring we continue to bring fresh, quality baking to communities across Scotland,” explains John Bayne, the company’s

”What I observed in many bakeries from the 1960s to 2000, including high-profile and quality establishments, was that Bayne’s stood out as one of the most modern bakeries in Scotland and likely the UK.”

Joint Managing Director. Looking ahead, the bakery plans to continue expanding steadily, with two to three new shop openings per year over the next decade.

Bayne’s entered the Edinburgh market in 2012 and expanded into Glasgow in 2018. In 2021, the company launched its first drive-thru in Hillington. A few years ago, in 2023, Bayne’s completed a freezer extension at its bakery, which further enhanced its production capacity to meet growing demand.

The company has strived to stay attuned to its community and meet their preferences with interesting offerings, including convenient products, premium coffee and home delivery services. The second-generation owner, Stanley Bayne, noted: “What I observed in many bakeries from the 1960s to 2000, including high-profile and quality establishments, was that Bayne’s stood out as one of the most modern bakeries in Scotland and likely the UK.” And it aims to continue to innovate, with plans including investing in digital transformation and product innovation.

Stanley Bayne, chairman, Bayne’s the Family Bakers

© Bayne's

“At Bayne’s, our customers are at the heart of everything we do, for instance through our popular coffee card reward program, which offers a free coffee for every eight purchased,” shares John Bayne.

All Bayne’s products are still crafted in Fife, at its central bakery in Lochore. This facility has evolved over the years, combining traditional baking methods with modern technology to support a growing network of shops. Freshly baked goods are prepared, packed, and distributed each morning.

Bayne’s specialties are available for home delivery via apps such as Just Eat, Uber Eats and Deliveroo, offering a wide selection of products, from breakfast rolls to sweet treats. Online orders can also be placed directly on the bakery’s website, for click-and-collect in shop.

Modern and fun: meet Baynesy

The bakery embraces modern trends in all aspects of the work they love, from creating new products and adopting trends and innovations, to how they relate to their customers. Baynesy has entered the scene on the 70th anniversary as proof of that, the bakery’s new animated mascot. It was created together with Lewis and Tayburn, one of Scotland’s leading creative agencies, and personifies a fun and friendly family baker whose mission is to bring joy.

Baynesy has large shoes to fill and the fit is perfect: as a representative of the joy of great-tasting Scottish specialties, he embodies the warmth and heritage of Bayne’s bakery and brings a contemporary and playful twist to the anniversary achievement.

A lot of care went into creating the character, to craft the version that best engages with consumers in the digital space and unmistakenly captures the spirit of Bayne’s. Ricky Stevens, Creative Director at Tayburn said of this project: “We wanted to ensure that Baynesy not only reflected the rich heritage of Bayne’s but also had a fresh, digital-first personality that could evolve with the brand. We understand that brand characters create warm emotive connections with the audience which increases brand recall, so this was a big part of our thinking behind Baynesy.

Using advanced animation techniques, the teams envisioned Baynesy as much more than just a static figure – he’s a lively and interactive presence designed to evolve with Bayne’s brand identity. Whether through playful motion graphics on social media or interactive online integrations, Baynesy’s digital-first approach makes him a standout addition to the bakery’s marketing strategy.

The bakery’s long-term goal is clear: to continue growing responsibly while preserving the family values and product excellence that define Bayne’s. +++

Reproducibilty

PREMIUM QUALITY

Freshly baked goodness

With the occasion of a special milestone for Bayne’s the Family Bakers, John Bayne shares the company’s work behind the most recent shop opening and expanding the network.

+bbi: Bayne’s marks its 70th anniversary with the opening of its 70th shop. How is an expansion project carried out?

John Bayne: Reaching our 70th shop in our 70th year is an achievement that we are incredibly proud of. Selecting the right location is crucial for our continued growth, and we worked closely with our trusted property agent, Alastair Rowe at EYCO, who has helped in identifying prime locations over the past four years. Inveralmond Retail Park in Perth stood out as the perfect fit – it offers high footfall, excellent visibility, and convenient parking, all of which contribute to a seamless and enjoyable customer experience.

As with any new opening, there were challenges to overcome with the preparations, from logistical planning to ensuring it was fully stocked and operational from day one. However, thanks to the dedication and expertise of our team, the transition was managed smoothly, allowing us to continue delivering the high-quality service and products Bayne’s is known for. The shop opening has created 14 new jobs for the local community.

For us, expansion isn’t just about numbers – it’s about maintaining the quality, service, and family values that have defined Bayne’s for the past 70 years. Our priority will always be delivering the best possible products and experience for our customers across Scotland. Each new location will be carefully selected to align with the brand and meet customer needs.

bbi: What products are sold in the new shop? Are the same product ranges available in all shops?

Bayne: The new Inveralmond shop offers our full Bayne’s range – everything from our award-winning morning rolls and classic steak pies to freshly filled rolls, sweet treats, and our popular premium coffee.

bbi: When founder John Bayne brought the bakery in 1921, the initial plan was to make steak pies for Glencraig miners in the Lochore area. What is the family’s story since then, in baking?

Bayne: Bayne’s story began with my grandfather, John Bayne, and his brother Bill, who started selling beef in the Lochore area before opening their first butcher shop in Glencraig. In 1954, My grandfather spotted an opportunity to buy the nearby bakery to make steak pies for the miners. From the very beginning, he operated with a strong set of principles – efficiency, high standards, and respect for people – which became the foundation of our business. Today, Bayne’s is a proud third-generation family business.

my grandfather founded the bakery, my father, Stanley Bayne, took over in 1964, guiding its growth and expansion. Now, I have the privilege of working as Joint Managing Director. Our strong family values and unwavering commitment to quality have been passed down through each generation, ensuring that Bayne’s remains true to its roots while continuing to grow.

bbi: What were the first products developed? What is the oldest-running product today? And what new interpretations has it received over the years?

Bayne: Our earliest products were steak pies and morning rolls. The morning roll remains our longest-running and most iconic product, beloved by generations of customers. Over the years, we've expanded this classic, offering filled breakfast rolls.

bbi: And what are some of the most popular products today? Bayne: Our morning rolls remain a favorite, a timeless classic. Other top sellers include steak pies, sausage rolls, and empire biscuits. +++

After

© Bayne's

Bakers inspire bakers

One of the most important roles a trade show can hope to fulfill is to provide the platform where ideas spark. While bakers get inspiration for new creations from new trends, their unique experiences and their customers, at iba they can share their experiences. The show’s owner, the German Baker’s Confederation, shared with bbi their perspective on the German baking industry and how bakers can share know-how and inspire bakeries worldwide, at iba and every day.

+The German Baker’s Confederation (Zentralverband des Deutschen Bäckerhandwerks) is the owner of iba. It represents the interests of almost 9,000 bakeries, which have 235,000 employees between them. With a total turnover of EUR 17.92 billion, the German baking industry is one of the influential economic sectors in Germany. Roland Ermer, President of the German Baker’s Confederation, shared the organization’s views.

Catalina Mihu: Artisan bakery is a top priority at iba. What are the main priorities of artisan bakers in Germany today?

Roland Ermer: Germany is known worldwide for its bread culture, and artisan bakers are proud of this. With over 3,000 bread specialties, our businesses are not only basic suppliers in the regions, but also provide high-quality products – some with recipes that have existed for

generations, often paired with a great deal of creativity and a joy of experimenting. These valuable assets must be preserved, and the German Baker’s Confederation stands up for it every day. Core issues currently include the omnipresent shortage of skilled labor, securing an affordable energy supply and a significant reduction of bureaucracy, which paralyzes many businesses.

Mihu: How do German artisan bakers tackle ongoing challenges?

Ermer: Entrepreneurs in Germany are fighters – they stand up for their company and their employees and always try to find new solutions, even in difficult situations. The guilds, together with their regional associations, are in intensive dialogue with politicians, just as we are as the German Bakers Confederation. This requires perseverance, good

”Entrepreneurs in Germany are fighters – they stand up for their company and their employees and always try to find new solutions, even in difficult situations. The guilds, together with their regional associations, are in intensive dialogue with politicians, just as we are as the German Bakers Confederation.”

Roland Ermer, President, German Baker’s Confederation

public relations work and constant, respectful insistence. We hope that the new government in Germany will once again raise awareness of SMEs as a reliable pillar of our economy. Our companies create jobs, secure prosperity in the regions and also ensure social interaction in their shops and cafés. Only together as an association organization can we be perceived as a strong voice to stand up for our interests.

Mihu: How should the legislation improve the support for Germany’s artisan bakeries?

Ermer: First and foremost, we are convinced that the Working Time Act must be adjusted, as it represents a competitive disadvantage for our businesses: On Sundays and public holidays, for example, we are only allowed to produce for three hours – this is far too little for a proper range of goods and therefore a clear advantage for industrial manufacturers. However, security of supply is also important: we are dependent on grain that is suitable for baking – the tightening of the fertilizer ordinance would pose a threat to supply. To this end, we are calling on politicians to provide planning and investment security for energy sources, deregulate bureaucratic tasks as well as reform tax and social law.

Mihu: And how does the German Baker’s Confederation work to convey the industry’s point of view – regarding the support it requires? Please highlight the lobby activities.

Ermer: We have always been in close dialogue with the specialist departments and the relevant ministries. The offices of the Member of Parliament are familiar with our points of view thanks to our claims papers and personal discussions, and we never get tired of fighting for the interests of our companies. This also includes appropriate public relations work in social media, press statements and many examples in practice.

Mihu: How does the German Baker’s Confederation collaborate with similar organizations in Europe? Please share details about recent/current activities, for a Europe-wide outlook of current projects.

Ermer: With CEBP, the European umbrella organization for bakers and confectioners (Confédération Européenne des

Organisations Nationales de la Boulangerie et de las Patisserie CEBP), we have a strong organization so that we can bundle all interests in Europe and represent them clearly in Brussels. This includes the Europe-wide reduction in bureaucracy as well as the ‘Act on Corporate Due Diligence Obligations in Supply Chains’ (‚Lieferkettensorgfaltspflichtgesetz‘ in Germany) and corporate sustainability reporting.

and

All bakery roads lead to Germany

Working and learning together, as a community, does not stop after an event that lasts a few days, it is a part of the everyday work. Susann Seidemann – Head of iba, shows how the exhibition and the people behind it can help support this communication.

+Mihu: How can international artisan bakers use iba to connect with their European colleagues –throughout the year? What kind of assistance can iba’s platform provide throughout the year, as a running service in between exhibitions?

Susann Seidemann: We created the new iba platform aiming to bring all industry participants together throughout the year as well as improve the way of preparing for and following up on the trade fair. Users who register receive personalized news automatically and can network with other participants. Visitors who are searching for solutions can find the right partners, products, or exhibitors. The iba platform supports scheduling; additionally, contacting and networking features increase the effectiveness during the visit, when meeting international colleagues. After the trade fair, the exhibitors can stay in contact with visitors. They can strengthen customer contact and increase their reach through automated follow-ups. Altogether the platform connects the players before, during and after the trade fair.

At the trade fair, visitors have numerous opportunities to network, e.g. at presentations and discussion panels in the iba.FORUM, on the iba.STAGE, in the iba.DIGITALISATION AREA, or at pitches in the iba.START UP AREA. Here you will meet like-minded colleagues and visitors. Additionally, participating in evening events is the best way to make valuable personal contacts. Here I recommend the iba.NETWORKING NIGHT, the BAKERS NIGHT and the iba. BÄCKER Party, which are for visitors and exhibitors and the iba.EXHIBITOR EVENING, which is for exhibitors. These new events will take place in the iba.EVENT AREA in the evening directly after the trade fair closes. Tickets are sold online. The charming, relaxed atmosphere of a wooden alpine hut makes it easy to get into conversation with colleagues, customers, or companies from all over the world. And colleagues can connect also at a European level like at the CEBP, and their members meet at iba. The Annual Conference CEBP is a meeting of the European Federation of Bakers and Confectioners (Confédération Européenne des Organisations Nationales de la Boulangerie et de las Patisserie CEBP). It is a platform to exchange issues affecting the European bakery trade and to represent interests more strongly in Brussels. Members of CEBP are affiliated through their national association. For example, in Germany, the German Baker’s Confederation (Zentralverband des Deutschen Bäckerhandwerks) is a member of the CEBP, which represents individual companies.

Mihu: In line with the ‘Baking New Ways’ theme chosen by iba this year, what emerging innovations are promising to be successful?

Seidemann: Through the focus topics of artisan bakery, digitalization and food trends, iba highlights the main trends and offers future direction. In the area of artisan bakery, everything revolves around traditional and modern craftsmanship and vocational training. When it comes to digitalization, iba presents new methods for the baking industry: from process optimization and automation through artificial intelligence to the possibility of increasing customer loyalty through new sales channels. The topic of food trends looks at new products that are being launched and the possibilities offered by alternative ingredients. Successful innovations will mainly be around digitalization and automation in production, sales and logistics. Additionally, products that will reduce costs of resources, such as new options in raw materials, are promising to be successful.

Mihu: How are unusual, unique experiences and shop concepts defined? What inspiration can be found at the trade show this year, in this regard?

Artisan Breads / Bread & Buns / Tortilla, Flat Bread & Snacks / Pizza & Pastries

Biscuits, Crackers & Energy Bars / Sweet Goods, Cakes & Muffins

Every step of the baking process matters. From mixing to proofing to baking to decor, our brands offer cutting edge solutions

Together, we push boundaries to create the next generation of deliciousness.

Seidemann: Unusual shop concepts are required for exceptional artisan bakeries. Quality and functionality are combined with design. Sustainability is also important: renewable raw materials such as reed, wood, bamboo, or cotton are increasingly being used. To counteract the shortage of skilled labor and generate sales even after the shop closures, there are solutions such as hybrid shop concepts consisting of a classic bakery sales counter with an automated sales system that is accessible through a separate shop entrance. Baked goods, bread and drinks are ordered via a self-order terminal. Other future ideas can include fully air-conditioned ‘Tiny Stores’, which can be used to test out potential new locations, for instance. The mobile, fully equipped container-based supply bakery includes a snack preparation station, warehouse, staff room, oven space, and shop window.

”Fermented sourdoughs also remain a hot topic: baker’s yeasts that fulfill consistent quality standards and enzyme-based baking solutions that are tailored to the needs of bakeries.”

Susann Seidemann, Director, iba

Digitalization is an important issue in the stores. It ranges from automated production processes to online orders, pre-order deliveries and apps, from digital inventory management (such as software solutions for logistic optimization or new technologies to optimize energy) to digital marketing, or data analysis through Artificial Intelligence, i.e. by analyzing customer preferences or returns optimization. Inspirations can be found at iba.DIGITALISATION AREA in hall 14, where the bakery of the future is showcased by letting visitors test digitalization and new possibilities. Always on the lookout for future concepts, iba is also launching a new design competition this year – ‘Bakery of the future’, on the subject of shop fitting. The prizes for the best ideas will be announced on May 20 in the iba.FORUM.

Mihu: What new product concepts will reflect current trends?

Seidemann: iba has three main focus topics, that reflect the current trends: Digitalisation, artisan bakery and Food

Trends. In hall 15, there will be a brand new concept, the iba.FOOD TRENDS AREA, where exhibitors present the latest food trends, from innovative raw materials and baking ingredients to snack ideas and healthy ingredients. Flavor remains the main trend in product concepts. In the rapidly evolving baking industry, challenges such as nutritional optimization, sustainability and consumer demand must be overcome without compromising on taste. At iba, visitors can discover new flavor trends and chocolate combinations. For example, they will find versatile fruit and cream fillings for all types of baked goods or high-quality, dairy-free whipped cream.

Fermented sourdoughs also remain a hot topic: baker’s yeasts that fulfill consistent quality standards and enzymebased baking solutions that are tailored to the needs of bakeries.

And those who love colorful baked goods or desserts will also find what they are looking for: toppings with colors of natural origin impress with their tasty chocolate content. Further ongoing trends are the focus topics sustainability and health.

Mihu: What inspiration can the industrial sector get from artisan innovation?

Seidemann: Industrial bakeries could draw inspiration from traditional artisan bakery practices to enhance products and processes in several areas: in fermentation and flavor development (i.e. long fermentation, or incorporating sourdough starters or yeast preferments to enhance taste and texture); in ingredient simplicity (i.e., usage of diverse, high-quality flours, including ancestral and local wheat varieties or focus on simple, natural ingredients without unnecessary additives or preservatives); or, in production techniques, such as gentle dough handling using equipment for stress-free dough processing to maintain dough structure integrity.

And, of course, the other way around: artisan bakeries can be inspired by innovations of the industrial sector, for example by solutions in digitalization or automated systems. One thing is for sure – nobody will leave iba 2025 without inspiration!

We welcome all visitors and exhibitors to take a deep dive into innovations, get inspired by each other's solutions in the baking sector, connect with partners and bring business to the next level! +++

Pretzels with an automated twist

Pretzels are an undisputed staple in many European markets. They are instantly associated with craftsmanship, for a reliable snacking choice. For production consistency, automation that replicates the craft is the challenge. The MULTITWIST system by FRITSCH earned awards for the technology solution used to produce perfectly twisted pretzels.

+Forming twisted products is one of the most demanding and, at the same time, labor-intensive and time-consuming manufacturing processes in the production of any baked goods. FRITSCH researched how to automate this process and developed the twisting unit for a rich collection of products requiring manual shaping, for highvolume production and product diversity.

Trendy pretzels and the extended family of creations

The unit is at the heart of the MULTITWIST system: using two grippers, the machine not only twists pretzels in various shapes and sizes, but also sticks, rings and labor-intensive products, such as single-strand braids and knots. One twisting unit can reach an output of up to 2,000 pieces per hour, when producing pretzels and ring-shaped specialties. Up to 1,500 pieces of twisted knots and single-strand braids can be processed per hour.

The pretzels can vary in size, shape, weight and the placement of the twisted ‘arms’. A pretzel is never ‘just a pretzel’, the specialist points out: “There are also regional differences to consider; for example, whether a pretzel has a thicker section, a ‘belly’, or not. We also see a higher demand for pretzels made of sweeter doughs, such as brioche.” The FRITSCH system can even customize the positioning of the pretzel’s ‘arms’.

With a growing trend for greater variety in terms of shapes and sizes, in addition to the classic pretzels, customized

twisting tools are designed, depending on the intended product ranges. Solutions for rings, single-strand braids, knots, and pretzel buns – these are only some of the frequently-asked custom solutions for the FRITSCH twisting machine.

“Especially when it comes to sizes, trends can vary considerably, from large 10 oz to small snack products such as small knots with a weight of 40 g,” the specialists from

FRITSCH explain. Pretzel buns are also a popular variety – a very tightly twisted pretzel, often topped as a kind of roll. “The FRITSCH MULTITWIST can reliably produce these tightly twisted pretzel buns with a capacity of up to 2,000 pieces per hour,” they highlight.

The latest product added to the capabilities of the MULTITWIST is the so-called ‘10 oz pretzel’, with a dough weight of approx. 330 g. Such large pretzels are popular varieties, usually seen at folk festivals or sports events. They could only be produced manually before FRITSCH adapted the process to the MULTITWIST, the company says. The challenge with developing the right process for this product came from handling the 800 mm-long dough strand as it was transferred to a 650 mm-wide infeed table leading to the twisting unit. To achieve this, the strand is first formed into a U shape before, and then it can be twisted into a pretzel. The capacity of a twisting unit for 10 oz pretzels is 1,200 pieces per hour.

The list of specialties the MULTITWIST can process continues to grow: “New end products are constantly being developed, for which we develop matching, connected components,” the specialists note. Depending on the design of an existing line, bakeries also have the option to expand them in product variety.

Energy savings were also pursued, among regular developments to the MULTITWIST: “The efficiency class of the three-phase AC drives has been adapted to IE3 over time,” FRITSCH highlights.

Different, but consistent

Several features ensure the results will be in the desired parameters, for consistency in all shapes and sizes. Some variations may occur before the dough arrives at this processing stage; for consistent forming results, upstream processes must be calibrated to provide pieces of dough of consistent characteristics, at the right time.

When that doesn’t happen, there are options for sorting out sub-standard dough strands: “The MULTITWIST system is equipped with a centering and ejection system (center device) to ensure that dough strands that do not match in length or are not centered on the conveyor belt can be sorted out or aligned. Here, the dough strands are visually scanned by a camera and the shape and length of the strand are checked. If the parameters do not match the set values, the dough strand is rejected by criteria of length, centered placement on the conveyor belt, or strand symmetry,” FRITSCH specialists explain. Guide plates are installed at the transfer points, to ensure that the dough strand always runs straight into the molding plates. All these steps ensure the twisting process is carried out efficiently.

The common denominator

Consistent pretzel quality starts with consistent dough forming. Dough strands are the basis for all MULTITWIST products. The system uses cylindrical or conical dough strands, which are molded from a coiled piece of dough using a strand machine.

One more step upstream, the dough arriving at the pretzel strand machine is first round-molded and pressed flat with a special device. The flat piece of dough is then coiled, for the stranding machine, where a two-stage molding process is set up, with a molding board. A strand of dough is now created – the common denominator of all pretzel-like products. They can have different shapes, from cylindrical to conical or bulbous, for different styles of end products.

Tool changeovers

To swap between products, the current twisting table and its respective tool have to be replaced with the one corresponding to the next specialty. Changeovers are

”The latest product added to the capabilities of the MULTITWIST is the so-called ‘10 oz pretzel’, with a dough weight of approx. 330 g. Such large pretzels are popular varieties, usually seen at folk festivals or sports events. They could only be produced manually before FRITSCH adapted the process to the MULTITWIST.”

FRITSCH specialists

designed to be made without the need for special tools, in a straightforward process that only takes a few minutes.

Safety features are in place to ensure the tool used and the associated program are a match, with all twisting tools monitored via RFID modules. “The MULTITWIST is able to recognize whether the tool being used matches the program that has been set. If it does not, the line displays an error to avoid damaging the toolset,” FRITSCH highlights.

Twist and bake!

For industrial production, FRITSCH can design a layout with several twisting modules running in parallel, making the MULTITWIST system very flexible in terms of output: “A single twisting module is capable of producing up to 2,000 pretzels per hour. Depending on the customer's requirements, a MULTITWIST can be combined with up to 10 twisting modules, representing a piece-per-hour performance of up to 20,000,” the specialists from FRITSCH illustrate.

The production is replicated at the desired scale, consistently. The process steps on maximum-capacity industrial lines could be set up as follows: 10 rows of dough pieces are transferred from a pre-proofing cabinet with an upstream dough divider. A distribution system with individual conveyor belts is then used to feed the twisting sections, the same process used for single lines. After flattening and coiling the dough piece, the strand is molded with the pretzel strand machine and then twisted to the requested product. Afterward, the products are deposited onto a common conveyor belt, which transfers the products to the downstream process via a discharge unit. Pretzels are ready to be baked and enjoyed. +++

Smart sourdough baking starts here

Establishing a complete setup for sourdough production in industrial bakeries poses several challenges. The fermentation process must be taken into account and the equipment must be able to replicate handcraft techniques to handle this delicate dough.

+Once a specialty synonymous with craft bakeries, artisan products are now in high demand in the baked goods aisle, too, as a better-for-you alternative to products that are traditionally produced in industrial volumes. It’s not just bread: artisan-style products comprise any products with a handmade feel and carefully selected, simple ingredients, that are usually found in local bakery shops. They can range from crusty sourdough loaves to buns with different seed assortments or braided rolls. Sourdough specialties are among the baked goods that continue to amass a dedicated following of loyal admirers (and consumers).

However, processing sourdough in industrial operations must cater to the sourdough’s properties for consistent results that can successfully capitalize on this trend. The right equipment will support the production of sourdough

products (and a suite of other artisan-style products). Emerging solutions make use of Artificial Intelligence tools and machine learning to predict and adjust processes, for example. Vision systems also bring valuable insights to production, while process improvements with the use of robotics are also on the rise. Adaptability is key.

Defining the technology lineup for sourdough starts with a comprehensive analysis of the products on the to-bake list: building a mono-line that will process the one specialty 24/7 will be approached in a completely different way compared to a line that will be used for an entire assortment of products which use dough of similar characteristics with sourdough, for instance. The flexibility needed will contribute to the setup of the line, as will the process management needs.

Delicate dough: handle with care!

Artisan sourdough bread is praised for craftsmanship for good reason. The dough is often very delicate and requires an experienced hand to handle it to enhance its properties and avoid harming its structure. Absolutely no stretching or breaking is allowed.

Baking sourdough?

+ Baking curve: product-specific, set to decline. For example: 280/255/230°C, depending on the bread type.

+ Airflow: typical air speed between 1.5-3.5 m/s (coloraider/ convection)

+ Humidity (moisture should always be ensured at the beginning of the baking process:

- Without steam, dewpoint at 60°C

- With steam, around 80°C dewpoint

- Ending at 20-40°C dewpoint

Establishing an optimum process flow is fundamental to timing each step with respect to the dough’s development. “Streamlining processes is made possible by controlling each process in detail, to match the type of product and its requirements. The dough determines the settings of the line,” AMF’s specialist underlines.

In high-volume operations, “For sourdough and any highlyhydrated doughs, gentle reduction in the sheeting process is key to determining the design of an automated line,” AMF Bakery Systems’ specialists underline. Such gentle handling can be ensured with the AMF Tromp sheeting lines, which can be finetuned for all types of dough in the artisan-style category. The AMF Tromp Stress–Free Artisan (SFA) Bread Line is designed specifically for this purpose, with dough-reducing technology that maintains the dough’s integrity throughout the process.

Low-stress sheeting and rolling out of the dough sheet mean its properties will be kept intact. “As much as possible, the

bubbles and the process inside the dough must be allowed to develop undisturbed. In this way, the dough can quickly recover to its ideal characteristics,” AMF underlines. This is ensured by recipe-driven, automated lines, with a single point of control for the entire process. Quick changeovers also ensure a smooth production flow, essential for high-volume operations. The AMF Tromp sheeting line does not require any tools for changeovers, to expedite the process and ensure safety. It also comes with recipe-driven software, for efficiency and convenience in use.

Full-scale craftsmanship

To mass produce crusty products that are found in artisan bakeries, sheeting must be accompanied by the correct processes upstream, when the dough is created and developed, and downstream, when the products are baked.

AMF’s horizontal mixers, for example, can work in optimum conditions with doughs of any consistency, including soft and delicate sourdoughs. They monitor the mixing process at every stage and, with the help of the company’s dedicated Dough Guardian, a patented technology, adjustments can be made in real-time, to ensure consistent results over time. In addition, “AMF Fusion has kneaders and mixers that are suitable for sourdoughs, but also fully-automated fermentation

systems, using AGVs, fermentation rooms, large dough bins, and software to monitor this process, with no human interaction needed,” they explain a possible line-up for a true ‘bakery of the future’.

”Streamlining processes is made possible by controlling each process in detail, to match the type of product and its requirements. The dough determines the settings of the line.”

AMF Bakery Systems specialists

Proofing can also raise challenges for sourdoughs, which need accurate resting control to develop the coveted artisan rise and crust. Here, AMF can offer a range of systems to choose from, including step, spiral, or continuous proofers. “We accommodate high-hydration and long fermentation times for dough, to create those nice artisanal products, with lots of bubbles inside and crusty outside,” AMF highlights. Even dough with no fermentation times can be processed: they can be sheeted directly on the line, if flexibility is needed.

AMF can provide several oven technology options in the AMF Den Boer range, to complete a sourdough line. Stonefloor ovens are a popular choice currently for any artisan specialty, and Den Boer ovens include them, along with precise burner control and gap detection technology, to ensure product uniformity. Direct-fired gas ovens are also very popular choices. “We see a rise in impingement technology (indirect), electric and hydrogen baking, or hybrid models to combine fueling options,” AMF observes market dynamics. These technologies ensure the consistent production of crusty specialties.

Decorations are the finishing touch for handmade creations, and they can also be automated, from scoring various patterns to sprinkling seeds or nuts, and even applying glazes. All these systems feature material recirculation solutions, so no costly ingredients go to waste. “Using seeding, (water) scoring for a crusty top, enrobing seeds on the bottom, are trends we see more and more in premium products,” AMF specialists observe. Decoration choices for beautiful creations are many, from seeds to nuts and fruits. Depending on the product, inclusions can also be added to the dough, for example, by mixing in olives.

And, to always have a view of the complete process, AMFConnect can provide a digital map of the entire line, with smart features to ensure process flow continuity. The company developed Bakery Intelligence solutions that cover everything from mixing, make-up and proofing to baking, cooling, conveying and packaging.

These kinds of lines are built for large volumes: average large sites easily run 2 tons of mixed dough per hour. “Our sheeting lines by TROMP can handle these volumes,” AMF specialists note. They are engineered and configured to specific needs, and aligned with existing processes or equipment.

To establish the optimum equipment setup, testing can be carried out first, at the AMF Innovation Center, to validate products at full-scale. A team of bakers and food technologists can support testing there, along with ingredient suppliers. The rest is up to the imagination, to envision and create unique sourdough specialties that convey an artisanal look and feel. +++

A second article on sourdough will be published in the next issue of Baking+Biscuit International.

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+In the past, breadmaking faced challenges with mixing consistency in the UK because the flour commonly used was quite weak and a lot could change with the environmental conditions in the bakery while the dough was resting in the bowl. Plus, moving the bowls around was a labor-intensive task.

The Chorleywood Bread Process (CBP) was developed at an eponymous research center in the ‘60s to meet these exact challenges. It was so efficient and quick at producing bread that it conquered the British bread industry – and for good reason. It was first adopted by artisan bakeries and then industrial operations followed. It went in a different direction than traditional dough production, which called for a slower pace and often included long fermentation times. Instead, the CBP uses high-speed mixing with intense mechanical activity. This works with weaker flour and, usually, additional yeast, so that the dough can withstand the shorter process and, by using vacuum – more water. Time is saved from the mixing speed and the significantly shorter fermentation times – with additives sometimes also added to compensate. The result after baking: bread with a light, airy texture.

Royal Kaak developed a range of dedicated mixers to principles of the CBP, aptly named Mechanical Dough Developers (MDD). The difference with this technology is that it improved the high-speed mixing process so that it can be used for a wide variety of products, aside from sandwich and toast bread – including many different specialties, such as breakfast products, soft buns, flatbread, breadcrumbs, rusks and even brioche and yeast-raised donuts, for example.

A complete process

The MDD is a complete high-speed mixing system, continuously updated to comply with all present-day standards. It

Dough developing

Faster and better

Faster production, cost efficiency and quality consistency: these are the advantages that made the Chorleywood Bread Process such a success. Designed to perfect it, Royal Kaak’s MDD mixers also support an entire range of products that can enjoy the same production benefits, from buns to pizza, donuts and brioche.

is built in an enclosure for improved hygiene and lower noise levels. Ingredient handling and dosing are integrated, including a weighing capability.

”We are not measuring mixing by time; we are mixing on energy. We do so because this method eliminates the risk of under-mixing or over-mixing.”

And, for the mixing process itself, vacuum is used to achieve products with a finer cell structure; alternatively, applying pressure results in a more open structure. Vacuum makes the air inside the dough expand with the change in air pressure. Mixing will then cause the air bubbles to divide into smaller ones. Repeating this sequence will result in having small air pockets evenly distributed throughout the dough. A different mechanism is triggered when using pressure: as the gluten network is formed while mixing, it holds on to the gas bubbles that are forming. By adding more oxygen into the enclosure, the gluten network strengthens and is able to retain the air bubbles, which, in turn, expand as the yeast is proofing, forming larger air pockets, respectively a more open product structure.

Why was this design choice made? Ton van der Pas, Product Sales Manager, Royal Kaak, explains: “It’s because we are not measuring mixing by time; we are mixing on energy. We do so because this method eliminates the risk of undermixing or over-mixing, in case the exernal silos do not provide the mixer the exact amount of flour as expected.”

The MDD measures the flour, water and other ingredients

Ton van der Pas, Product Sales Manager, Royal Kaak

all pictures

© Royal Kaak

going into the recipe, with a method: first, the flour is brought in, and its weight and temperature are recorded. In parallel, water is pre-weighed and most of the needed amount is added, at the same time. According to final flour measurements, the remaining quantity of water, at the correct temperature, is added to the flour – for both weight compensation and temperature correction that are needed to achieve consistent results. The result will be a constant quantity and quality of dough over batches. In addition, the mixer itself is designed for efficient cooling during the mixing processes when needed, with a double-jacketed bowl as a standard feature.

The pressure and vacuum system allows for accurate control of the product texture and makes the mixer flexible for a wide range of products. “Adding pressure is an optional feature for our mixer. It comes with vacuum, as standard, and we can also apply pressure if required. In this case, the build

of the mixer has to be adapted to the use of pressure,” the specialist explains.

The mixing process itself is adjusted according to the measurements and the dosing optimization, respectively: “A well developed dough requires a certain amount of energy (watt-hours per kg). Depending on the exact quantity of ingredients in the bowl, the mixing process will take more or less time to reach this result, on the premise that the same amount of energy is always applied to the dough,” he adds. In combination with the automated water temperature regulation, it gives the constant dough quality that the industrial bread production process requires.

When the mixing process finishes, the dough is ready to be discharged. The MDD also incorporates dough handling, which is done with a skip hoist – an inclined ramp that conveys the newly formed dough to downstream processes.

The MDD mixers can process batches of up to 462 kg of dough, making them a great option for high-volume production. Ideally, the batches should be as small as possible, the specialist notes: “The smaller the dough volume, the less of a head-tail effect you have. Since a lot of the dividers are volumetric, if density changes because of the yeast, product weights will also change.” Not only does this system mix fast, in about 3 minutes, but also in quick succession: while it is mixing a batch, the upcoming one can already start, by preparing the ingredients of the next selected recipe. The system can be completely automated, so no labor is required at any stage.

Fast mixing stays fast if the cleaning is also done quickly, and Kaak’s MDD has a unique feature allowing speed cleaning – but thorough, nonetheless. The cleaning tool is connected to the bowl and cleans it with high-pressure water. The bowl can be quickly filled, then drained, and it is ready to get back to work. There are several cleaning programs available, for various cleaning needs. Since it’s a closed system, dust, flour buildup, or any unwanted particles cannot access the mixer frame. The mixer itself is designed for high hygiene standards, to allow wet cleaning.

The MDD integrates complex features but remains easy to use correctly: its 3D PLC control allows the recipes to be controlled with complete accuracy and mixing parameters can be configured for the products, according to testing results. The quality will then remain constant. +++

Ingredient Handling & Dosing System (IHDS)

Bowl cooling

Patented CIP system

MDD Mixer Family

Source: Royal Kaak

The total package

Selecting a packaging concept for baked products is a task with an extensive checklist. Functionality, safety and design are only the tip of the iceberg. Although not immediately visible to consumers, packaging choices are important. Adding sustainability to the list of criteria makes the challenge even more complex.

+ The biggest sustainability improvements in packaging solutions greatly vary from one market to another, especially when it comes to labels and closures. They can include solutions that reduce material use, smart labeling, materials that are compatible with the recycling practices available, or reusable closures, to name just a few examples.

Kwik Lok works extensively on R&D in sustainable solutions for packaging closures and labels. The Enviro-Lok, for instance, one of the newest developments in this regard, reflects this priority in its characteristics and its name. The company takes a systematic approach to designing science-based sustainable solutions. Research at Kwik Lok starts with evaluating the environmental impact of packaging solutions through life cycle analysis (LCA) screening. “These assessments consistently show that material selection offers the greatest potential for sustainability improvements,” Viktoria Pakhnyuk, Sustainable Product Development Manager, points out. As a result, Kwik Lok focuses on expanding material options within its product portfolio to look into developments that help customers meet their sustainability goals, on any market.

What makes bag closures sustainable?

Kwik Lok analyzes sustainability throughout the lifetime of its bag closures, the company explains: “When considering raw material sourcing, Kwik Lok incorporates recycled content or bio-based materials where accessible.” As new materials are developed and validated, the company looks into local supply availabilities, too, for each manufacturing plant to limit transport (while preserving quality consistency).

”Assessments consistently show that material selection offers the greatest potential for sustainability improvements.”

Viktoria

“Kwik Lok also considers the packaging’s end-of-life fate like recyclability or compostability and pursues materials that have the potential for these more sustainable disposal options,” Pakhnyuk underlines.

The regulatory landscape is also a determining factor for packaging material choices. Because priorities vary from one geography to another, Kwik Lok offers products that can meet different sustainability goals, whether regulations measure packaging composition, weight, or other metrics. With different variables, the goal stays the same: to limit environmental impact. Beyond regulation requirements, Kwik Lok is taking its own bigger sustainability steps voluntarily to offer packaging choices in the supply chain. Retailers with ambitious sustainability targets, for example, are looking at such solutions with great interest, Kwik Lok observes.

This is how the latest bag closures, the Enviro-Lok and Fibre-Lok concepts, were developed, with sustainability in mind. Their design prioritized multiple aspects:

Pakhnyuk, Sustainable Product Development Manager, Kwik Lok

+ Enviro-Lok, Kwik Lok’s first plastic closure free of polystyrene, is made from polypropylene with 34% less plastic, reducing reliance on petroleum-based materials. Over its lifetime, the Enviro-Lok has achieved a 67% reduction in water usage and 44% lower emissions, compared to traditional closures.

Additionally, it can be paired with a polypropylene label through a patented adhesive-free welding process, enhancing recyclability.

+ Fibre-Lok offers an alternative made from bio-based materials. Certain Fibre-Lok options feature 100% postconsumer recycled fiber or Forest Stewardship Council (FSC) certification for responsible forestry practices. Some variants are even certified for home composting, providing an alternative to landfill disposal.

Mindful of different understandings and priorities surrounding sustainability in each market, Kwik Lok offers the Enviro-Lok and several Fibre-Lok options worldwide, in addition to its traditional polystyrene bag closure. “No single product will meet all possible sustainability requirements, rather the trade-offs of each option must be evaluated

according to established priorities. For example, the durability of plastic compared to fiber makes it a better choice under wet conditions. Customers must also consider how Kwik Lok’s product complements the composition of their entire package, like flexible film bags, to meet recommended packaging design criteria,” explains Viktoria Pakhnyuk.

Sustainability and efficiency combined

Beyond sustainability factors such as water usage and carbon emissions, considerations including cost, efficiency, and durability are equally important. “Each material has unique properties that present both benefits and challenges at various stages, from manufacturing and transportation to disposal. As sustainability remains a dynamic and evolving field, packaging trends can shift rapidly with new insights,” the Viktoria Pakhnyuk emphasizes.

Kwik Lok’s R&D working agenda prioritizes changing market demands and sustainability goals. Beyond material innovation, Kwik Lok ensures that all new closures are compatible with existing bag-closing machines, extending equipment longevity and minimizing waste. +++

Cutting-edge cutting

Optimizing bread recipes and fine-tuning their production will guarantee the best results, consistently. Between this bread and perfectly cut sandwich-ready slices is the right blade.

+ When slicing bread in industrial-scale operations with automated systems, an efficient setup means clean cuts, with minimum damage to the product. Accuracy is a must and, to achieve it, the blades should match the characteristics of the bread, while ensuring the correct spacing for the desired slice thickness is set up.

Soft bread, for example, is best cut with thin blades, to minimize the amount of crumbs that break off. But, when slicing bread with a well-defined crust, a thicker blade is the better tool; the same goes for more dense bread varieties. Then, material choices are also available – for the blade itself and its coating, where one is used. The shape and pattern of the blade’s cutting edge are also important considerations when matching blade with product: either serrated, straight, or rounded.

Hansaloy designs blades for all types of breads and buns – and their corresponding slicing machines – according to the properties of each type of product, in terms of crust, texture and grain variety. The blades are designed for scoring that will result in smooth cuts, slices with consistent texture and shaped, as well as minimum product loss through crumbs. The key is matching the product with the best-suited blade.

Understanding slicing blades

Hansaloy uses two primary variables to match different types of breads, textures, and grains to the best slicing blade for the application:

+ Pitch: the distance between the peaks of the scallops along the edge of the blade, and

+ Edge: different kinds of blade edges (straight, serrated/ toothed, scalloped/curved) are specifically designed for various slicing applications.

Serrated edges can be provided with fine, medium, or coarse serrations, to match different textures of the bread. Scallop-edged blades, in turn, excel at slicing soft breads efficiently, maintaining the integrity of the slices. Straight blades, although occasionally used, are nevertheless a great option for applications including cakes and pastries, specialty breads such as gluten-free, or doughs. ©

Hansaloy

Looking at the blade for the product, Nick Blaser, VP, Sales, explains: “A standard cross-ground blade (the S or E edge model) is well suited for a variety of products. As the pitch is changed from larger (12.7 mm) to medium (9.4 mm) and smaller (6.4 mm) sizes, the blade will become more aggressive and do a better job of penetrating hard-crusted products.

A parallel ground blade (the H22 or H27 type of edge) is well suited for minimal crumb creation and extremely smooth slice quality. These blades go through an additional sharpening process that smooths the side wall of the blade edge, to reduce crumbing. And, as the pitch goes from larger to smaller, the blade becomes more aggressive, penetrating harder crusted breads.”

Alternatively, looking at the product’s impact on the blade, various types of baked products will impact the life and quality of the blades differently. “When evaluating the product being sliced, we review the overall quality of the blade to provide the best match, Blaser notes. “The nature of how bread is sliced is a torture test for a steel blade,” he points out.

To extend the lifespan of the blades, Hansaloy developed a steel alloy specifically for slicing breads and buns, and perfected it over the years. The steel alloy used by the specialist is designed to resist premature breakage while maintaining a razor-sharp edge over time.

Next, the blade manufacturing process must also allow for tight length control to ensure a consistent blade length, both within a box and from box to box. For this to happen, the blade manufacturing process must have quality checks along the way, Hansaloy points out.

Matching breads with Hansaloy blades

Blade pitch options:

+ 12.7 mm (1/2”): the most commonly used pitch, good for soft breads

+ 9.5 mm (3/8”): the best versatile pitch option, good for both hard and soft products

+ 6.4 mm (1/4”): originally developed for hard crust, Europeanstyle breads; suitable for a variety of breads specialties, especially firm breads

Moreover, the blade’s tension should be monitored and controlled, to ensure its lifespan is maximized. “Running blades at either high or low tension will introduce heat, which can lead to premature blade breakage. Having a system in place and using a Hansaloy mechanical or digital tension gauge will ensure proper tension and promote blade longevity,” Blaser recommends. When blades are replaced, their tension should be measured to ensure the slicer is operating within the recommended tension.

To manufacture the blades, Hansaloy uses a proprietary welding process with high-strength welds and precise band lengths. To ensure a consistent geometry of scallop, the blade specialist has developed its own grinding technology, with excellent results in the life of the blade band. For sharpness as well as extended edge life, blades undergo precision grinding and finishing as required by each model. Where needed, blade coatings can also be applied, for use in high-speed slicing. Hansaloy’s quality process has several built-in checks along the way to ensure consistent blade geometry, including checking the scallop profiles while blades are being made, the specialist details. The engineering of the blades not only ensures extended lifespans, but also lower maintenance needs.

As long as the product meets its best match in slicing blades, the ‘next thing since sliced bread’ is ‘better sliced bread’. +++

Source: Hansaloy

Emithermic ® XE baking is sustainable baking

The Emithermic ® XE technology was developed to deliver consistent, even radiant heat while maximizing thermal energy retention and overall efficiency. By eliminating all Direct Gas Fired (DGF) ribbon burners, the oven developed by Reading Bakery Systems (RBS) represents a major transformation in cracker baking.

+For well over a hundred years, snack food manufacturers have been baking biscuits and crackers in direct gas-fired (DGF) tunnel ovens. But, with increasing demands for efficiency, sustainability and productivity, come new technology developments to optimize the baking process.

RBS has developed a cracker-baking replacement for traditional DGF ovens – the Emithermic XE Oven. This technology is innovative because it eliminates all ribbon burners and delivers uniform heat distribution for an even bake across the width of the oven. It also allows for accurate moisture control, which is critical for a crispy cracker texture.

RBS specialists explain what makes this technology step a leap in cracker baking: “Traditional DGF cracker ovens are more difficult and costly to operate and maintain, and often produce an unevenly baked product. Operators must adjust and maintain a large number of ribbon burners to make sure the product is baked properly.” By contrast, the new Emithermic XE replicates the baking principle of a

”The Emithermic XE oven design uses a centralized penthouse to deliver heated air to Thermatec ® panels and convection nozzles to deliver balanced heat to the product. Electric radiant heaters can also be used to deliver the high radiant component required to develop the flavor and texture of the crackers.”

RBS specialists

DGF oven without the hassle of having to manage so many different ribbon burners. Traditional DGF ovens can have 30 control points in each zone, while the Emithermic XE oven has just 7. “The Emithermic XE oven design uses a centralized penthouse to deliver heat to Thermatec ® panels and convection nozzles to deliver balanced heat to the product. Electric radiant heaters can also be used to deliver the high radiant component required to develop the flavor and texture of the crackers.”

Emithermic XE oven at a glance:

+ Eliminates all ribbon burners

+ Improves product consistency

+ Automated, intuitive operator controls

+ Simplifies cleaning and maintenance

+ Humidity-controlled product zone

+ Gas ovens easily convert to electricity in the future

Advanced controls

Moreover, this oven also cuts energy consumption and emissions, improves process control and simplifies cleaning and maintenance. Like all RBS ovens, the Emithermic XE features RBSConnect. This is an Industry 4.0-aligned control system that eliminates variables inherent to operators manually finetuning the process. “Developed to simplify operations, RBSConnect automatically executes pre-set, recipe-driven controls. Bakers can easily configure and store recipe settings to ensure product and process consistency,” RBS specialists say. The RBSConnect system also monitors production in real-time and manages a Closed Loop Oven Control System that captures data on product flow rates, temperatures, energy efficiency trends, and other Key Process Indicators (KPIs). Ultimately, the system helps ensure a higher percentage of products with the desired characteristics and less waste on the line.

Easy cleaning and maintenance

The benefits of the Emithermic XE technology also extend to cleaning and maintenance. A DGF oven can have more than 300 burners, so cleaning and maintenance can be a serious undertaking. When each of these burners needs tuning or replacement, maintenance is time-consuming and can cause unplanned downtime and lost productivity. With fewer parts to maintain and integrated support from RBSConnect, the Emithermic XE oven makes maintenance simpler and more cost-effective. “Along with monitoring the product during baking, the control system also monitors the performance of oven blowers and motors, recording motor amps, speeds, runtimes, and more. With RBSConnect, operators are alerted to replace failing parts long before they result in costly line disruptions,” the specialists explain.

Forward-thinking technology

RBS developed the Emithermic XE Oven with sustainability in mind. After all, manufacturers installing the new oven will be using it for the next 20-40 years. Accordingly, the Emithermic XE Oven is available with a penthouse that can

be powered by natural gas or electricity. Manufacturers that opt for the gas-heated version today can easily convert the oven to all-electric in the future.

An Emithermic XE Oven has been installed in the RBS Science & Innovation Center for trial runs with measurable cracker and process results. +++

Emithermic XE at the RBS Science & Innovation Center

backaldrin earns EcoVadis silver

The baking ingredients manufacturer from Asten has improved on the previous year and is now among the top 10 % of companies rated by EcoVadis and in the top 4 % of the industry in their sustainability efforts, backaldrin announced.

For this achievement, backaldrin receives the silver medal. The achieved percentile rank of 90 also indicates that the company was rated higher than or at least the same as 90 % of all companies rated by EcoVadis. The “Sustainable procurement” area is also worth highlighting, for which the company was ranked in the top 6 %. It is also in the top 6 % in the “Environment” category, in the top 3 % in “Labor and human rights” and in “Ethics”, it is in the top 8 %. +++

Vandemoortele to buy Délifrance

Vandemoortele and Délifrance agreed to establish themselves as a new, joint player in the frozen bakery market, with the Belgian family-owned group acquiring the French baker. The acquisition will create an estimated EUR 2.4 billion global player. By joining forces, they will be able to offer a complete range of viennoiseries, Danish pastries, artisanal bread, donuts, Italian savories, and patisserie products under leading brands including Délifrance, Banquet d’Or, Doony’s, Lanterna, Acquaviva and Lizzi. Délifrance is one of Europe’s leading frozen bakery manufacturers, with over 3,200 employees, a network of 14 production sites and an annual turnover of approximately EUR 930 million for the year ending June 30, 2024. Délifrance’s main markets are in Europe and Asia. +++

Koenig expands international sales team

Koenig expanded its sales team: Kai Wörzler and Stanislaw Selich will join the sales team at Koenig Deutschland GmbH, while Filippo Comerio and Martin Gallot will expand the international sales team of the Koenig Group. The new employees have many years of experience in the industry and are familiar with the requirements of bakeries worldwide. The new team members can already be contacted for sales and project support. The Koenig Group has around 750 employees. +++

New Chairman for Zeppelin

From April 1, Sascha Stiller took over as Chairman of the Management Board of Zeppelin Systems GmbH and Head of the Strategic Business Unit (SBU) Plant Engineering. Stiller will also be responsible for all subsidiaries worldwide. He succeeds Dr. Markus Vöge, who retired.

Since July 2023, he has served as Managing Director of Zeppelin Systems USA, Inc. based in Florida. In his new role as Chief Executive Officer (CEO), he will join Ralf Boschert (CFO) on the Management Board of Zeppelin Systems GmbH. +++

Syntegon relocation plans advance

Syntegon sold its former site in Waiblingen to Andreas Stihl AG & Co. KG, moving on with its plans to relocate its production and administration activities to Fellbach and Bad Cannstatt (Stuttgart) this year. The strategy is in view of further growth. The purchase agreement was signed on March 31.

Syntegon will establish its central administrative branch in a Business Excellence Center in the Stuttgart district of Bad Cannstatt in the third quarter of 2025. The new offices are close to Stuttgart’s main railway station and airport. +++

© Koenig

Kai Wörzler (left) and Stanislaw Selich (right) strengthen the sales team in Germany

© Zeppelin

Sascha Stiller

By Euromonitor International

+According to Euromonitor International’s World Market for Snacks 2024 report, 18 % of adult Indians, 17 % of adult Americans and 13 % of adult Britons have been replacing their meals with snacks, as convenienceoriented lifestyle changes favor snacking and consumer purchases continue to be impacted by economic uncertainty. One in six adult residents of the United States is replacing their daily meals with snacks, data from the study reveals, with UK, Singapore, US and Brazil all registering strong increases in the ‘snackification’ trend.

Carl Quash III, head of snacks at Euromonitor International, said: “Consumers have been under unprecedented stress these past few years with the cost-of-living crisis among a number of other challenges. Snacks have been leveraged for comfort and stress reduction by providing consumers entertainment at gatherings, joy as affordable gifts or presents, and pleasure as self-treats or rewards.”

US and UK increasingly favor snack consumption over meals

The year-on-year growth underscores a significant shift in consumer behavior, reflecting changing dietary preferences. In the US, the percentage of residents replacing meals with snacks has risen from 14 % in 2023 to 17 % in 2024, marking a growth of 3 %. The UK has also seen a notable increase, with the proportion of adult residents replacing meals with snacks rising from 10 % in 2023 to 13 % in 2024. Singapore, Canada and Brazil all registered strong growth in meals being replaced with snacks, showing a 3 % increase for each market.

While many countries are experiencing growth, India showed a notable decline in the percentage of residents replacing meals with snacks, dropping from 21 % in 2023 to 18 % in 2024.

A knack for snacks

Global snack sales surpassed USD 680 billion in 2024, Euromonitor International estimates show. While North America contributed to 28 % of all global snack sales in 2023, India remains the world leader in snacking habits.

”The motives driving consumers to snack are expanding and manufacturers are intersecting these new occasions and intents with offerings that provide opportunities for broader consumption throughout the day.”

Carl Quash III, Head of Snacks, Euromonitor International

India’s snack market is undergoing premiumization and affordability changes simultaneously. However, India remained the top country in the study for snacks replacing meals, with almost one in five adults opting for snacks instead of meals.

More snacks!

The global market for snacks is expected to see sustained value growth, with retail sales projected to surpass USD 680 billion in 2024, up 3.7 % from 2023 in constant value prices, the research shows. North America leads with a 28 % share of global snack sales in 2023, owing to a high demand for innovative and convenient snack options. Asia Pacific followed at 24 %, with Western Europe at 23 %.

Emerging regions like the Middle East and Africa are forecast to lead snack value growth with a CAGR of 4.6 % from 2024 to 2029. These regions are experiencing a rapid increase in urbanization and disposable incomes, driving demand for a wide range of snack products.

Quash III added: “The motives driving consumers to snack are expanding and manufacturers are intersecting these new occasions and intents with offerings that provide opportunities for broader consumption throughout the day.” +++

Product quality, industrial performance, and sustainability. At MECATHERM, we aim to support you everyday as you explore new ideas to stay ahead, and overcome challenges while reducing your carbon footprint.

We are developing numerous innovative and sustainable solutions to optimize your energy efficiency throughout your entire production line. Let’s discuss and discover the array of options awaiting you. BOOTH

UNDERSTANDING SOURDOUGH

Fedima’s mission to build a common ground

Sourdough is one of the oldest kinds of bread, with a delightful variety of flavor notes and a distinctive tangy taste. A formal, working definition of sourdough is, surprisingly, not crystallized, given its rich history. Classifications may be a difficult endeavor, but, a common understanding helps bakers and consumers.

+Sourdough production is a traditional bread-making practice, that, until the middle of the 19th century, was the main way to make leavened bread by fermentation. Sourdough carries strong cultural and traditional aspects, which have been preserved throughout the years. This has led to a large variety and diversity of sourdoughs available on the market nowadays, as well as a difficulty in the classification and definition of sourdough in different European markets due to its inherent use as a leavening agent and/or for its organoleptic properties.

No general consensus or harmonized European understanding can currently be observed. However, despite this variety and differences, a common understanding in the industry on the forms and the use of sourdough can be found, and Fedima is at the forefront of promoting it with its “Understanding Sourdough” paper, aiming at wide endorsement among different industry players.

According to Fedima, alignment on this common understanding is essential in order to ensure the protection of the interest of consumers, and safeguard the integrity of the term ‘sourdough’ and its heritage while securing the functioning of the internal market. Fedima defines sourdough as a characteristic food ingredient obtained from flour of cereals or pseudo-cereals, fermented by microorganisms –mainly lactic acid bacteria and yeast – without the addition of acids to artificially adapt the acidity.

In the consumer-facing context, the priority should be to provide them with transparent information while valorizing

#SourdoughCampaign

To promote sourdough and inform consumers about the many fascinating characteristics of this ingredient, Fedima put in place a #SourdoughCampaign featuring four inform ative videos about sourdough's history and properties.

the baker’s process. Taking bread as an example, Fedima defines sourdough bread as bread fermented with sourdough or with sourdough and bakers’ yeast. On the other hand, bread (prepared) with sourdough as bread fermented by bakers’ yeast and containing sourdough as an ingredient bringing typical organoleptic characteristics. Its quantity is the one recorded after the sourdough fermentation. In this case, the sourdough is listed as an ingredient in accordance with EU’s food information to consumers legislation. +++

PROACTIVE PARTNERSHIP

>> THAT KEEPS YOU A STEP AHEAD

Coperion unites the leading technology brands in food manufacturing to deliver innovative system solutions for your bakery.

Technology for:

• Systems & Ingredient Automation

• Pre-Dough, Mixing, Baking, Forming & Dividing

• Dosing, Decorating & Cutting

Curiosity drives innovation

As cetravac celebrates 25 years of working in the baking industry, Baking+Biscuit International analyzes with its founder, Adolf Cerma k , the opportunities of the unique, patented vacuum technology perfected by cetravac and bakeXperts. We delved into what truly revolutionary, disruptive ideas mean, from the perspective of an engineering specialist. Together, we also looked into what shapes the future of innovation in bakery and how a technology developer stays innovative over time.

+ Current developments

Catalina Mihu: Vacuum cooling specialist cetravac, together with its sister company bakeXperts, are synonymous with the unique UDO oven. What are the latest technology updates it currently incorporates, and where could it go next?

Adolf Cermak: We introduced three new models at südback 2024, with different capacities: the Shop-UDO ovens, working with 6 trays, with 2 x 6 trays and 15 trays, all coming with rack loading systems to minimize loading times and to have the products on all trays baked at the same time. It is a big advantage compared to having the products in the first tray nearly/already baked, while on the 15th tray, they are still frozen. Racks that can be directly pushed into the oven are available for bigger setups, and can already be seen at Aldi and in other supermarkets, for example. However, artisan bakers can also have this option now, with the new models. The first bakeries to use them are already carrying out tests.

A high-speed UDO snack oven will be shown at iba in Dusseldorf. It can bake and cool down a frozen pizza to a ready-to-eat temperature, in only two minutes, with no microwaves involved – meaning that the structure of the dough remains intact. This is the main difference compared to other high-speed ovens, which work with microwaves.

Mihu: What are the R&D priorities of each company?

Cermak: bakeXperts is introducing the three new oven models I mentioned. The next step will be to advance from PLC technology to a print control system. PLC was useful as we were making changes to the program, but it is an expensive solution.

At cetravac, we are working on budget-friendly versions of the vacuum conditioning systems. A smaller, entry-level vacuum cooling model with all the basic features can be

accessible to hundreds of smaller, artisan bakers, who are not yet potential customers. A smaller bakery does not necessarily need 12 batches per hour, and, perhaps, they may not need automatic sliding doors. If you leave out some of these convenience functions, the process result will, nevertheless, be the same. Entry-level models can be designed to fit between 6 to 8 batches an hour, while delivering the same benefits in terms of quality, freshness, energy and labor savings. By comparison, the current equipment can fit 10-12 batches/hour.

Adolf Cermak, helped develop the vacuum baking and conditioning technology.

The DACH region

Mihu: Vacuum technology is gaining ground in the Germanspeaking countries. How was the UDO oven received in the DACH region, where it is already known, and what are some of its applications there?

Cermak: The specialist stores that use the new oven models are able to bake and cool frozen dough 40% faster. They use the UDO for croissants, Danish, or rolls. In addition, they can also double-bake products, so that the bread that remained unsold at the end of the day can regain its freshly baked properties the next day. This is possible thanks to the patented starch re-gelatinization process that allows products to be fully restored, minimizing food and raw material waste, as well as associated energy and time.

Mihu: What makes vacuum conditioning and baking particularly successful in this region?

Cermak: I don't know of any other region where bakeries produce such a wide range of baked goods in their stores. Bakers here are used to selling their customers warm, fresh out-of-the-oven products (and not products just delivered for sale). The UDO also offers a great advantage, especially when working with inexperienced staff: the employees simply take the products out of the freezer and place them in the oven - that's it! Steps such as defrosting or proofing

are taken out of consideration. The same applies to vacuum cooling in production, as it helps with the production of parbaked goods, which the UDO then bakes quickly and to a very high quality. Combining vacuum cooling with baking is the key to success in the future.

“You can only find ways to bring about real change if you remain curious throughout your professional life, question the status quo and are prepared to leave your comfort zone time and again. Developing new products and bringing them to market is hard work. And sometimes it also becomes an extremely expensive 'hobby'.”

Ideas drive the business forward

Mihu: What was the concept behind establishing cetravac?

Cermak: There was not one crystalized concept, but an idea I was discussing with a baker/scientist friend about two

Experience cutting-edge solutions at iba 2025! From bread variety and pastries to snacks and trend products – our smart and connective technologies for dividing, depositing, forming, and automation set new standards. Visit us and explore the future of baking!

Adolf Cermak, founder, cetravac, bakeXperts

years before founding the company, namely how interesting cooling applications were in the 70s. Back then, vacuum cooling was used to cool down tin breads so they could be sliced better and faster. The technology had virtually disappeared from the market back then, because the vacuum pumps at the time were quite rudimentary and there were no suitable control systems (PLC) that could be used to control processes in such an accurate and versatile way. With this idea in mind, I developed a small test system for vacuum cooling, which delivered promising results. This is how cetravac started.

Mihu: So it all started from a fortuitous but useful conversation?

Cermak: Yes. As I was carrying out the first tests, I quickly became convinced that this would be a technology for the future; in the early 2000s, the industry was just starting to talk about new trends such as parbaked and frozen dough products. Vacuum cooling could be helpful in this, I thought. It was the right idea and the right time.

Mihu: And how has cetravac developed vacuum technology since then?

Cermak: We were about 10-15 years ahead of the market, with our concept. For new ideas to grow, you must always find someone who wants to do the pioneering work. At the start of the 2000s, we found customers in various countries, from Austria, Germany, Luxembourg and America, to Japan and Russia, who wanted to be the first to try something new, like vacuum technology. But a breakthrough was still a long way off.

We further developed the technology for over a decade, before the first vacuum chambers were purchased in German and Austrian bakeries for their usefulness, and not because they wanted to be the first. The next step was a new idea, based on vacuum cooling: the development of an oven with integrated vacuum cooling so that the chamber could be used for baking and cooling.

We designed an oven with a vacuum-proof baking chamber, a vacuum pump and a steam generator. During our first tests, the core temperature of the bread rose from 20 to 80 °C in just one minute. After analyzing this phenomenon, it was clear to us that we had discovered something very special. We confirmed that this unique process developed in this way consistently. Thanks to the re-gelatinization of starch, in a now patented process, there is no loss of product weight, and baking time and energy consumption are significantly reduced. This is one of UDO's core competencies. With the competition coming from supermarkets that were offering freshly baked bread, bakeries needed to set a clear differentiation in product quality – to justify having higher prices than discounters; and, with vacuum baking and cooling, the products have better quality, they stay crispy for longer, and have a longer shelf-life when stored at ambient temperature. This was the beginning of the path on which we are now – a provider mainly focusing on the DACH region.

Mihu: How did bakeXperts follow as the second company to be developed in 2013?

Cermak: bakeXperts was established as a bakery engineering company, to separate a clear focus and take over tasks that were the responsibility of cetravac, initially. As cetrevac’s vacuum cooling success story was beginning, in 2012, it was important for us to concentrate our effort on vacuum conditioning. That's why we founded bakeXperts, for our planning tasks.

In 2021, with the decision to bring the UDO out of the experimental stage and onto the market, we decided to leave the planning business to others and push the UDO. That is when bakeXperts shifted its focus to vacuum oven development.

Mihu: With new processes and new technologies, a training and adjusting process is usually expected. What training do you offer for the UDO oven technology?

Arno Tiggelbeck, Head of Application Technology; Veronika Grebner, CEO; Gero Friedrich, Site Manager North, Head of Product Management

Cermak: We have recently started organizing seminars here, in Switzerland, as well as in Austria and Germany, to explain the technology. Our application engineers, who work for both cetravac and bakeXperts, will be on hand to provide customers with help and advice on-site.

Mihu: What is the reach of the two companies today?

Cermak: We focus on the DACH market, but also reach the UK, Denmark, Sweden and Norway. Our headquarters remains in Altstätten, Switzerland, while we are increasingly relocating our production sites to Germany, to Wildeshausen near Bremen and Dortmund.

Mihu: Do you anticipate an expansion in the coming years? And how do you envision the company in 2025 and beyond?

Cermak: Definitely, we want to expand. At cetravac, we will proceed rather cautiously, while at bakeXperts the upcoming iba trade show will set the pace. I myself am planning to entrust cetravac to the competent hands of three of our most deserving employees as part of a management buy-out. My successors are forming a management team with an average age of under 40. At the same time, we are preparing for another milestone: 25 years of exhibiting at iba, which we will celebrate this year in Düsseldorf. The

start for us was iba 2000, back then in Munich. I'm looking forward to it.

“A great environment”

Mihu: Why did you decide you wanted to build your expertise and an entire career in the baking industry?

Cermak: I worked for around six years in industrial refrigeration, for companies in Germany and France. Then, rather by chance, I came across a job offer from one of the bakery refrigeration pioneers. That was at the time when the first retarder/proofers were being developed. I took the opportunity, and got to know an industry that has stayed with me, even after such a long time. It's great to be able to work in an environment where everything smells so good and tastes appetizing! There is hardly anything like it. I was also impressed by the bakers themselves and their down-to-earth attitude.

Mihu: How did the transition from working in the baking industry to starting your own business go? After all, it's a big step.

Cermak: The reason why I did it is certainly down to my character: I have an allergy to bosses (laughs). I often realized that I would solve tasks differently than they were

usually solved, or even better than ‘the way things were always done in the past’. That was certainly the most important reason.

Mihu: What advice would you give to young engineers at the start of their careers?

Cermak: When you are an engineer with a degree, you are a potential inventor. So, you should be one! A good engineer always questions things and thinks about how they can do something better.

Curiosity sparks ideas: “Never stop wondering”

Mihu: Vacuum is one of the pioneering solutions for bakeries. Which technological innovations from the last 30 years would you highlight that have brought similar major advances to bakeries?

Cermak: The invention of retarder-proofers, around 3040 years ago, was such a step. With this technology, the dough was automatically defrosted and brought to proofing. Fully automated retarder-proofers were the biggest gamechangers. I was involved in the development and market launch of this technology at the end of the 1970s. As I was working on it, I learned the timeline for a new idea to enter the baking industry: it’s about 15 years. This is why I was not surprised when vacuum cooling followed a similar path. In the artisan bakery business, there is no other comparable milestone, in my eyes.

Before that, in the 1960s, the invention of the rack oven was an outstanding achievement. Alongside vacuum cooling, both achievements have been the biggest game-changers. Of course, there are many innovations in the areas of automation, processing and dough preparation, but these are mostly just further developments.

”The oven is sensational. The estimation of the daily requirement of fresh baked goods is, despite the use of various software tools to reduce food waste; it is often a difficult undertaking. With the UDO, the bread can be partially baked in advance, and then have it fresh every day, as required, from the vacuum oven. The bread supply does not even need to be refrigerated and can be stored directly at room temperature for several days. The crumb is fresh and the crust is crispy. The water content of the bread after the final baking corresponds to that of the baked bread“

Prof. em. Dr. Dr. e. h. Friedrich Meuser, TU Berlin

Mihu: What role did your background in research and engineering play in your work to develop new solutions?

Cermak: My studies played a certain role in my understanding of mechanics, physics and process engineering. But to be able to do what I have done, curiosity is the most important prerequisite; curiosity and the willingness to leave your comfort zone and find ways to improve things. Only then can you find new paths. Developing new products and launching them on the market is hard work. And sometimes it becomes an extremely expensive ‘hobby’. Success is never guaranteed.

Mihu: And how did it help in your day-to-day work, in putting together the technical teams that work on developing vacuum cooling and baking?

Cermak: The answer is in finding like-minded people with a pioneering spirit, who share this curiosity and are team players. We still do this, every day. Unfortunately, such people are becoming increasingly rare and that won't get any better in the next few years. That's why at cetravac, we are only planning a really cautious expansion. Our goal is to create a product that brings multiple benefits to the customers, because this is the most convincing argument for it to be used. From this point of view, it is always easier when an entirely new product is brought to the market, rather than one in a category or similar solutions. The price is only the second argument.

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Solutions to meet changing challenges

Mihu: What makes the UDO exceptional in its baking efficiency? How would you compare today’s biggest challenges in bakery to the most prevalent ones in the past 30 years?

Cermak: Artisan bakers had almost no competition, 30 to 40 years ago. There was no Aldi, Lidl, or industrial baking. In addition, there was also no shortage of skilled workers. Today, we are looking at a completely different picture: the fewer young people who do enter the workforce now, also bring new expectations along, especially related to working times, in an industry particularly known for working nights. Out of necessity, bakeries are being forced to rethink new working models and bring work into the daytime. This makes technology all the more important. Robotics is one solution to the problem, vacuum cooling and vacuum baking are another. The need to adapt and find new working time models also applies to us. Our application engineers work for three weeks and have the fourth week off, to compensate for the weeks when they were often away from home visiting clients, working more than eight hours per day, including travel time. The model has established itself well, which is why we are introducing a similar model for our technicians in service and assembly.

Mihu: What effect did this change have?

Cermak: Everybody has a life outside of the office and it works well for our employees and for the company, too. They like to work for us and do their job well.

Mihu: In what areas of the industry do you see potential for innovation in the future?

Cermak: I think cooling and freezing will probably have incremental improvements going forward, but robotics will grow. There will be many new robotics start-ups in the industry. I think we will already be able to see this at iba this year, because of its great potential. There are many tasks that robots can take on. What is happening today is just the beginning.

Mihu: From the perspective of staying curious and always searching for improvements, what emerging ideas do you think will bring improvements, especially for in-store and artisan bakeries?

Cermak: A possible scenario is that many smaller bakeries could join forces to form production cooperations. Each could focus on the production of one product group and supply the others. This could result in considerable savings on equipment and more efficient production capacity utilization. I have recently seen a number of companies starting out with pre-purchased frozen dough. From the freezer, the products are placed on trays and go into a retarder-proofer, and, from there, to the oven, followed by vacuum cooling and distribution. In other words, the bakery only consists of a frozen food storage unit, a fully automatic proofing machine, rack ovens, vacuum cooler, packaging, order picking and dispatch. Raw material storage, flour silos, mixers and processing lines are nowhere to be found. And the quality of the products is quite impressive. This workflow could save significant investments in equipment and create a lot of room for automatization, using excellent-quality frozen dough that is already available.

In Germany, bakers organize experience exchange groups, where 10-12 bakers transparently share all their business information with their colleagues, including earning figures. Such groups could also evolve to form production cooperation groups that work in a similar way, in a completely collaborative model, rather than competitive. This could lead to substantial savings. However, not only could production become cheaper, but it also has the potential to achieve better results with a higher level of consistency, at the same time.

Mihu: To summarize our conversation today, what do you think is the calling card of cetravac and bakeXperts?

Cermak: We are leaders in vacuum cooling and baking technology, with a proven, partially patented technology. With the new, smaller vacuum chiller units that are now under development, we will further strengthen our position in the market. In addition, we will remain a reliable partner and innovation driver for the baking industry in view of our young new management generation.

Mihu: Thank you for an enlightening conversation, and see you soon, at iba! +++

Production in Wildeshausen/Germany: Up to four vacuum systems can be assembled at the same time

Unique products, by any measure

The potential of using measurement technology in bakeries is underestimated, says Dr. Banu Sezer, Market Development Manager Food at Anton Paar in Graz, Austria. However, completely new possibilities are opening up, especially in conjunction with AI.

+According to Dr. Banu Sezer's observations, measurement technology and quality assurance are sometimes viewed as secondary priorities. “Neglecting quality assurance, however, can lead to disappointing results and have negative impacts in the short to medium term for a company.”

Depending on the size of the operation and process complexity, bakeries in Europe use different measurement technologies. The most important parameters in quality assurance and control include: the moisture content of flour; the consistency of the dough; the performance of the baking agents/improvers; baking temperatures and times,

Analytics and measurement technology relevant to bakery production

Measuring instruments for quality control from Anton Paar

Measuring instrument Flour and dough analyzer

Function Measures the water absorption capacity of the flour and the consistency of the dough by assessing the resistance it exerts against the kneader’s mixing motion

Applications: (raw material/ semi-finished product)

Flour, improvers for bread and biscuits

Analysis is used for: By analysing the dough consistency and stability, it is possible to predict the kneading behaviour and adjust the water content in order to achieve the desired dough structure. The results expressed in standardized Farinograph units (FU) provide a basis for flour evaluation and and enable adjustments in recipes and production processes.

Dough processing and baking behavior analyzer

Device for examining the stretching and processing properties of a wheat dough

Flour, baking agents, improvers for bread and biscuits

For optimal dough processing, it is crucial to assess elasticity, extensibility, and resistance to stretching under real production conditions. Measuring these properties provides insights into how dough behaves during fermentation, shaping, and baking. This analysis is particularly useful for evaluating the influence of flour quality, fermentation time, and additives on dough performance. The results are provided in Extensograph units (EU).

Universal torque viscometer

Measures the gelling properties of starch-based products and the viscosity of various liquids

Flour and starch-containing material, chocolate and fillings

Quick viscosity analysis optimizes gelatinization and enzyme activity in doughs and starch-rich fillings. Assessing chocolate flow properties improves processing and prevents crystallization defects. Cooling behavior analysis predicts texture changes during production and storage. Real-time additive dosing enables precise recipe modifications for enhanced stability and performance. Results are reported in Brabender Units (BU) or mPas.

Brabender ViscoQuick

Brabender ExtensoGraph

Brabender FarinoGraph

as well as the texture, taste, appearance, and shelf life of the finished baked goods. More rarely, extended measurements of nutrient contents, microbiological analyses, and in-depth sensory quality analyses are carried out.

Dr. Sezer: “The immediate benefits of investing in measurement technology may not always be apparent, especially for bakeries that rely heavily on visual and tactile assessments. However, these measuring instruments not only ensure quality but also improve process efficiency and the proper use of valuable raw materials.”

In the broader industry context, global food safety standards are increasing the emphasis not only on quality assurance (product quality), but also on quality control (product safety) – especially in large-scale operations. “Regulatory

Function

Tests the viscosity of a variety of products

Applications: (raw material/ semi-finished product)

Chocolate, honey, syrups, plantbased dairy alternatives, thickening agents, fruit purées, and sauces

”The immediate benefits of investing in measurement technology may not always be apparent, but these systems not only ensure quality but also improve efficiency and the proper use of valuable raw materials.”

Measures the size of particles in both liquid dispersions and dry powders in the micro- and millimeter range

Powder and liquid ingredients (flavor, sugar, etc.)

Analysis is used for:

The viscosity analysis provides insights into the flow properties and consistency of liquids and semi-solids, ranging from low to high viscosities. Understanding these characteristics helps in optimizing formulations and ensuring uniformity in product texture, stability, and performance.

The analysis of particle sizes provides valuable insights into their distribution and behavior, with sizes ranging from nanoscale to millimeters. Understanding particle size is critical for optimizing product formulations, enhancing stability and improving performance in applications such as pharmaceuticals, food and coatings.

Measures the deformation and flow behavior of different samples

Eggs and dairy (milk, butter, yogurt, etc.), chocolate and fillings, coatings and moldings, whipped cream and mousses, stabilizers, emulsifiers, gelling, glazing agents

The analysis provides insights into properties such as shear, compressibility and wall friction, which are essential for understanding how powders will behave during processing and in the final product.

Dr. Banu Sezer, Market Development Manager Food, Anton Paar

Analytics and measurement technology relevant to bakery production

Measuring instruments for quality control from Anton Paar

MCR Rheometer

Litesizer DIF 500

ViscoQC 300 L

requirements, such as HACCP and ISO certifications, compel bakeries to focus more on maintaining quality through precise measurements“, says the expert.

The importance of AI is increasing

The use of artificial intelligence (AI) is transforming quality assurance (QA). In the production of baked goods, AI is now being used to detect irregular shapes, inconsistent crust colors, or incorrect portion sizes; to perform predictive maintenance of equipment based on historical data and sensor readings; to develop recipes, and to optimize supply chains.

Dr. Sezer says: “While AI is already being employed in these areas, there are many more opportunities for its integration, further expanding its role in quality assurance. For instance, AI-driven sensory analysis could revolutionize how taste, texture, and aroma are evaluated. Currently, human

Measuring instruments for quality control

Measuring instrument

Rapid small-scale oxidation test (RSSOT)

Function Tests the oxidation stability of a wide range of products, simulating real-world aging conditions

Applications: (raw material/ semi-finished product)

Analysis is used for:

Fats and oils, including powdered cocoa mass, liquid vanilla and peppermint extracts

The analysis of accelerated aging by increasing temperature and excess oxygen provides insights into the stability and shelf-life of various products. This test simulates real-world aging processes, helping to predict how materials such as food, flavors, fragrances, cosmetics and pharmaceuticals will degrade over time.

sensory panels are often used to assess these attributes, but AI could take over some of these tasks. By analyzing data from various sensors, such as gas sensors for aroma and texture analyzers for consistency, AI could simulate human taste testing and provide more objective, reliable feedback on flavor and texture.”

Highly customized baked goods

But that's not all. AI could also enable bakeries to personalize their products based on individual customer preferences, dietary needs, or emerging trends. Dr. Sezer adds: “By analyzing customer feedback, tracking preferences, and adjusting recipes in real time, AI could help bakeries deliver highly customized products that better align with consumer desires. This level of personalization would not only enhance customer satisfaction but also help bakeries stay competitive in an increasingly demand-driven market.” +++

Digital refractometer

An instrument for measuring the concentration and refractive index of liquids and pastes

Fluids, semi-fluids like plant-based oils, flavors, ingredients, and additives, sugars and sweeteners

Provides insights into the composition and purity of various substances. The analysis is crucial for ensuring consistent product quality, optimizing formulations, and verifying ingredient concentrations.

Used to analyze the spreadability of margarine and edible vegetable fats

The analysis of penetration depth provides insights into the consistency, hardness, and texture of materials. By measuring how different test bodies, such as needles, cones, rods, or discs, penetrate a sample, this test helps assess the material's behavior under pressure and its suitability for specific applications.

Analytics and measurement technology relevant to bakery production

from Anton Paar

Edible fats

PNR 12

Abbemat series

RapidOxy 100

Anton Paar will be exhibiting all instruments at iba, hall 10, stand H50.

A classification of leavening agents

Leavening agents, either biological, chemical, or steam, are essential components in baking.

By Dr. Alyaa Homoud, Head of Market Development (Flour & Baking), REDA Bake

+Leavening agents introduce gases into doughs and batters, improving volume, texture, and overall structure. These agents are categorized into biological, chemical, and steam-based types, each functioning through distinct mechanisms to create aeration (Gélinas, 2022).

1. Biological leavening agents

Biological leavening involves microorganisms that generate gases as metabolic byproducts, enhancing dough rise and contributing to flavor (Neeharika, Suneetha and Kumari, 2020).

Yeast fermentation

The most common biological leavening agent is Saccharomyces cerevisiae (baker's yeast), which metabolizes fermentable sugars through glycolysis, leading to the production of carbon dioxide (CO2) and ethanol via alcoholic fermentation (Liu et al., 2021):

+ Mechanism: CO 2 gets trapped within the gluten network, expanding the dough and creating a soft, airy texture.

+ Optimal conditions: Yeast thrives best at 25–35°C and a pH of 4.5 to 6.0 (Gélinas, 2022).

+ Factors affecting yeast activity:

- Sugar concentration: While yeast requires sugar for fermentation, high sugar levels cause osmotic stress, inhibiting yeast activity.

- Salt concentration: Excess salt can retard fermentation by dehydrating yeast cells.

- Hydration levels: Proper moisture content is crucial for yeast viability and gas production (Liu et al., 2021).

Sourdough fermentation

Sourdough involves a symbiotic relationship between yeast and lactic acid bacteria (LAB), primarily a species of Lactobacillus. LAB produce lactic and acetic acids, influencing dough acidity, taste, and texture (Cobbold, 2018):

+ Acidic environment: LAB lowers the dough’s pH, extending shelf life and enhancing gluten strength.

+ Flavor development: Acetic acid imparts tangy notes, while lactic acid provides a mild sourness (Lee, 2020).

Sourdough fermentation produces a more complex flavor and longer shelf life compared to conventional yeast-leavened bread.

2. Chemical leavening agents

Chemical leaveners rely on acid-base reactions to generate CO2 gas quickly, making them suitable for rapid baking applications like cakes, muffins, and quick breads (Gélinas, 2022).

Baking soda (sodium bicarbonate)

Sodium bicarbonate (NaHCO 3) releases CO 2 when it reacts with acids. A common reaction with acetic acid (vinegar) is (Liu et al., 2021):

+ Without acid: If used alone, sodium bicarbonate can decompose into sodium carbonate (Na 2CO 3), which imparts a bitter, soapy taste.

+ Acid sources: Common acids paired with baking soda include lemon juice (citric acid), yogurt (lactic acid), and cream of tartar (potassium bitartrate) (Gélinas, 2022).

“Steam functions as a physical leavening agent by utilizing water vaporization at high temperatures (Lee, 2020).”

Dr. Alyaa Homoud, REDA Bake

Baking powder

Baking powder is a pre-mixed leavening system consisting of:

+ Sodium bicarbonate

+ Acid salts (e.g., monocalcium phosphate, sodium aluminum sulfate)

+ Starch (acts as a moisture absorber to prevent premature reactions) (Neeharika, Suneetha and Kumari, 2020).

Double-acting baking powder

+ First CO 2 release: Upon mixing with liquid.

+ Second CO 2 release: During baking due to heat activation (Gélinas, 2022).

This controlled gas release ensures a steady rise, making baking powder a staple for cakes and cookies.

3. Steam as a leavening agent

Steam functions as a physical leavening agent by utilizing water vaporization at high temperatures (Lee, 2020).

Mechanism of steam leavening

1. Water in the dough reaches boiling point (100°C).

2. Expanding steam increases pressure, pushing against the dough matrix.

3. Protein coagulation and starch gelatinization stabilize the expanded structure (Cobbold, 2018).

Applications of steam leavening

+ Choux pastry (profiteroles, éclairs): High water and egg content allow steam to create large, hollow structures.

+ Puff pastry: Alternating layers of dough and fat trap steam, causing flaky texture formation.

+ Yorkshire pudding and popovers: The batter’s high moisture content leads to dramatic expansion (Lee, 2020).

Unlike yeast and chemical leaveners, steam is instantaneous and does not rely on fermentation or acid-base reactions. +++

References

Author

Based in Jiddah, Makkah, Saudi Arabia, Dr. Alyaa Homoud obtained her P.h.D. degree in Food Science and Technology at the Heriot-Watt University, in Edinburgh, Scotland (2015).

She is Head of Market Development (Flour & Baking) at REDA Bake, a manufacturer of a variety of specialty bakery ingredients for commercial baking operations.

At REDA Bake, food quality and safety are Dr. Homoud’s priorities. With expertise in food science, baking, and technology, she optimizes manufacturing processes and uses data analysis to enhance consumer health. The company operates regionally across the Gulf, North Africa, Levant, Sub-Saharan Africa, South Africa, South Asia, Central Asia, South-East Asia, and China.

She had a consulting role in a Vision 2030 project, focusing on sustainability practices and innovation, and advising on the implementation of cutting-edge food technologies.

- Gélinas, P. (2022) 'Gas sources in chemical leavening and other baker's yeast substitutes: lessons from patents and science'. International Journal of Food Science. Available at.

- Neeharika, B., Suneetha, W. J. and Kumari, B. A. (2020) 'Leavening agents for food industry'. ResearchGate. Available at.

- Liu, S., Song, J., Sun, M. and Sun, Y. (2021) 'An Analysis of Acid-Base Reaction and Fermentation-Induced Leavening Agents in Bread Making'. UBC Library. Available at.

- Lee, G. J. (2020) 'Change in height of breads baked by different type of leavening agents'. UBC Library. Available at.

- Cobbold, C. A. (2018) 'The rise of alternative bread leavening technologies in the nineteenth century'. Taylor & Francis. Available at.

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BECAUSE FACTS MATTER.

An olive branch

PhenOlives patented a process that allows leftover olives from the oil industry to be made into flour. This development has the potential to extend an olive branch to significant material waste in oil processing while providing a ‘super-flour’ with numerous benefits.

+The yield of oil made from olives is around 10-30 %, depending on the type of olive and the process itself. This leaves most of the harvested olives as a by-product. When it is estimated that as much as 90 % of the olives go unused by oil producers, the potential of efficiently repurposing them is great. The materials can be still valuable, aside from turning them into compost or animal feed.

The olive waste can become a nutritious olive flour that is gluten-free, high in fibers, low in calories and rich in antioxidants. It also has a neutral taste, making it versatile for use in diverse applications, and, via the patented process developed by PhenOlives, it is not only sustainable but also affordable. “One of the key aspects of PhenOlives' patented process is the ability to control the level of polyphenols in the olive flour, ensuring a balanced flavor profile that makes it suitable for a wide array of culinary applications. We optimize the polyphenol level at 2,000–4,000 ppm, which, based on trials and experience, effectively avoids any bitterness,” according to Chen Lev-Ari, CEO, PhenOlives.

All of the olive benefits, fewer of the product’s calories

As a key component of the Mediterranean diet, olives and olive oil have long been associated with well-being. Derived from upcycled by-products, olive flour has many functional benefits, thanks to its high-fiber content and gluten-free nature. “Rich in dietary fiber and polyphenols, olive flour supports digestive health and aligns with the growing demand for plant-based, health-conscious ingredients,” PhenOlives' CEO highlights.

It provides a nutritious gluten-free option while retaining great product texture and flavor, and it can

replace part of the carbohydrates in traditional flour-based products, the company observes. Combined with other traditional flour ingredients, olive flour can be used to create a variety of baked goods, with each product incorporating a different percentage of olive flour relative to the total amount of flour used: pasta (50 %), bread (20 %), crackers (100%), cookies (30 %), brownies (30 %), muffins (50 %), and pizza crust (50 %), the company illustrates.

“Rich in dietary fiber and polyphenols, olive flour supports digestive health and aligns with the growing demand for plant-based, health-conscious ingredients.”

Chen Lev-Ari, CEO, PhenOlives

The production process of the flour begins after the olive oil extraction ends. In this way, beneficial polyphenols (antioxidants) are preserved, while also significantly reducing the fat and calorie content. The flour is high in antioxidants, particularly polyphenols such as hydroxytyrosol and tyrosol. It is high in fiber, from the olive pulp, and low in fat and calories compared to whole olive or olive oil. It also contains minerals and trace elements from the olives.

Product inspiration

PhenOlives carried out tests on different types of products to test its feasibility and possible formulations: “When incorporated into baked goods and pasta, olive flour subtly enhances flavor at low percentages (up to 10%), while maintaining texture. At higher levels (up to 30%), it creates a denser, crumblier texture with a more pronounced olive taste, making it an ideal ingredient for bakers and food manufacturers looking to enhance nutritional value,”

Lev-Ari explains. The company’s research found that the flour proved to be versatile – it is suitable for a range of baked goods, from bread, pasta and crackers, to cookies and muffins. So far, PhenOlives has successfully incorporated olive flour into a range of products, including pasta, bread, crackers, cookies, brownies, muffins, and pizza crusts, using varying percentages of the flour.

The flour is suitable for various bakeries, from home bakeries to those on an industrial scale. The company is working with local chefs in Israel and across Europe to develop a range of new recipes using olive flour, and has received excellent feedback from them on working with it, they reveal. While possible product claims may vary depending on local regulations, the benefits of using the flour have been thoroughly tested. From the caloric values of the products, to their dietary fiber contents and antioxidant properties.

The expertise it can provide includes a library of tested recipe formulations, and ongoing technical assistance. Product development workshops are also organized, to share best practices. “Importantly, we also provide nutritional analysis and comprehensive ingredient information, ensuring they have everything they need for accurate labeling and consumer transparency,” he points out.

The process

The technology developed by PhenOlives prevents the oxidation of olive mill pomace. The system automatically separates the three key components of olive waste: seeds, pulp, and black water, directly within olive oil mills through advanced mechanization, the company says. “Unlike traditional methods, this process does not require chemicals, making it a truly natural and eco-friendly innovation,” Lev-Ari highlights.

By preventing oxidation at its source, this technology can make use of virtually 100% of the waste that would otherwise require disposal. “This not only reduces pollution caused by burning or landfill disposal but also provides a sustainable alternative for waste management,” Lev-Ari

underlines. It is not only an opportunity for bakers using the flour, but also for olive mills, which can convert waste into valuable products.

PhenOlives will collaborate with olive mills to source the materials: the company provides mills with a system that makes the by-products usable. Then, they buy these by-products and run them through their own systems to separate the three main components – seeds, pulp, and black water. The seeds are used for energy and other products in development, and the pulp is turned into olive flour. The research is ongoing: “And, we are currently researching new products based on the rich nutrients found in the black water, particularly the polyphenols, the company explains.

“With this system, every part of the olive is repurposed into commercial and nutritional products, reducing waste while increasing market value. Among these products, olive flour has become the flagship innovation. Unlike conventional flour sources, no additional olives need to be cultivated for its production—making it a sustainable and resource-efficient ingredient,” the specialist from PhenOlives observes.

The technology is a patented innovation in its home country of Israel and is in the final stages of patent approval in Europe. The company is collaborating with industry experts and can conduct pilot production trials in baking facilities to ensure a smooth integration, including sensory analysis and consumer testing to understand market feedback.

The company plans to install a number of PhenOlives systems in olive mills over the next few years, primarily in Europe. It anticipates that the first products with olive flour will be launched in 2026. +++

Smart technology solutions in the spotlight

Digitalization and artificial intelligence will receive special attention at iba, with several dedicated areas for modern software solutions that contribute to process optimization and customer service.

A highlight will be in Hall 14: the iba.DIGITALISATION AREA, where visitors can experience ‘the bakery of the future’ live, the organizers anticipate. “Digitalization increases efficiency, optimizes processes and improves interaction with customers and employees. In production, it helps to optimize processes – from the recipe and cooling control to the baking process,” iba details. Moreover, in sales, intelligent sales planning makes production more sustainable, and further digital services are available for various areas, such as cash register systems or hygiene management. AI solutions reduce staff workload, help increase sales and protect the environment. At iba, visitors can also experience how intelligent baking planning works: by analyzing demand in real-time, AI systems can plan which baked goods are needed and when, to greatly reduce food waste at the source. Visitors will learn how intelligent store assistants can support staff.

By using robotic solutions, AI automates production to help with workforce shortages while also keeping product quality at a consistently high level. In Hall 12, innovative bakery machines, systems and ovens will be showcased. Visitors specifically looking for exhibitors with IT and digitalization solutions can find them via the search function on the iba platform. In addition, exhibitor reports on this topic are shared online.

iba is also offering a comprehensive technical report on ‘Increasing sales with AI solutions’. +++

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Are you in the race? Are you one step ahead of the competition? How is your production going? Is everything working as smoothly as it should? The sum of intelligent and excellent elements can only work if the overall architecture is completely under control. We at Verhoeven Bakery Equipment Family look forward to meeting you at the upcoming IBA

the family labels have established a strong position due to innovative and creative turnkey solutions. We sell high-end production lines and state-of-the-art machines. Developed and made by a wonderful team of dedicated people. This makes us proud. We would love to show you why.

8. Freezing (optional)